Extrusion-coated structural systems having reinforced structural members

ABSTRACT

The present disclosure relates to extrusion-coated structural systems including one or more reinforced structural members, as well as methods of making and using the same. Structural systems of the present invention that include at least one reinforced member may exhibit enhanced strength, functionality, and/or durability, while being simpler to assemble and more aesthetic than similar conventional systems. Structural systems according to embodiments of the present invention can be suitable for use in a variety of applications, including as ready-to-assemble furniture or cabinetry or as building and construction materials such as wall board, flooring, trim, and the like.

CROSS REFERENCE TO RELATED APPLICATIONS

This application is a divisional of U.S. patent application Ser. No.14/496,483 filed Sep. 25, 2014, now U.S. Patent Publication Number2015-0110995, which claims the benefit of U.S. Patent ProvisionalApplication No. 61/892,592, filed Oct. 18, 2013, now expired.

FIELD OF THE INVENTION

This invention relates to structural systems. In particular, the presentinvention relates to structural systems useful as furniture and in otherapplications, as well as methods of making and using the same.

BACKGROUND

Ready-to-assemble items, such as furniture, shelving, and evenconstruction-related materials, are widely used by consumers in a numberof different applications. Although such items are generally moreconvenient than traditional items to manufacture, ship, store, andconstruct, conventional ready-to-assemble structures have room forimprovement, both in terms of functionality and aesthetics. Further,many ready-to-assemble structures lack strength and durability and,oftentimes, have a limited usable life, especially when exposed to heavyuse, rough service, and/or repeated assembly and disassembly. Oneproposed method of enhancing the strength, durability, and/or aestheticsof a ready-to-assemble structure is to apply a coating material to eachof the components of the system. Unfortunately, many coating materialsused in such applications exhibit poor adhesion to the underlyingsubstrate and/or fail to exhibit a desirable final appearance, resultingin an overall low-quality product. Other coatings are difficult to applyor can only be applied to relatively simple substrates having planarsurfaces without cuts, grooves, channels, or other complex geometries orgeometric features, greatly limiting the design and functionality of theresulting system.

Thus, a need exists for improved structural systems with greaterdurability, enhanced functionality, and a higher aesthetic value thatare also simple to manufacture, ship, assemble, and use. Preferably,such structures would also be capable of being produced bothconveniently and inexpensively, while still providing final productshaving a high level of quality.

SUMMARY

One embodiment of the present invention concerns an extrusion-coatedstructural system comprising a first structural member comprising asubstrate and a coating material extrusion coated onto at least aportion of the substrate, wherein the substrate comprises at least onestructural recess extending inwardly from a first outer surface of thesubstrate and a near-recess external surface at least partially formedof the coating material adjacent the structural recess, wherein thestructural recess is at least partially filled with the coating materialso as to reinforce at least a portion of the substrate, wherein themaximum thickness of the coating material at least partially filling thestructural recess is at least 2 times greater than the maximum thicknessof the coating material forming the near-recess external surface.

Another embodiment of the present invention concerns a method of makingan extrusion-coated structural system, the method comprising extrusioncoating a coating material onto at least a portion of a first substrateto form an extrusion-coated structural member, wherein the firstsubstrate defines at least one structural recess extending inwardly froman outer surface of the first substrate and a near-recess externalsurface adjacent the structural recess, wherein the near-recess externalsurface is formed of the coating material during the extrusion coating,wherein the extrusion coating includes applying the coating material tothe structural recess so that the maximum thickness of the coatingmaterial within the structural recess is at least 2 times greater thanthe thickness of the coating material forming the near-recess externalsurface.

Yet another embodiment of the present invention concerns a method forassembling an extrusion-coated structural system, the method comprising:(a) providing a first structural member; (b) providing a secondstructural member; and (c) joining the first and second structuralmembers to one another to thereby form at least a portion of thestructural system, wherein at least one of the first and the secondstructural members is a reinforced structural member comprising areinforced region proximate to the location where the first and secondstructural members are joined, wherein the reinforced structural membercomprises a substrate and a coating material at least partially coveringthe substrate, wherein the maximum thickness of the coating material inthe reinforced region is at least 2 times greater than the thickness ofthe coating material coated onto the reinforced structural member in thearea adjacent the reinforced region.

BRIEF DESCRIPTION OF THE DRAWINGS

Various embodiments of the present invention are described in detailbelow with reference to the attached drawing figures, wherein:

FIG. 1 is a schematic cross-sectional view of one embodiment of anextrusion-coated structural member having a reinforced region;

FIG. 2 is a side perspective view of another embodiment of anextrusion-coated structural member having a reinforced region;

FIG. 3 is a schematic cross-sectional view of another embodiment of theextrusion-coated structural member shown in FIG. 1;

FIG. 4 is a side perspective view of one embodiment of anextrusion-coated structural system including at least oneextrusion-coated structural member with a reinforced region;

FIG. 5 is a side perspective view of another embodiment of anextrusion-coated structural system including at least oneextrusion-coated structural member with a reinforced region;

FIG. 6 is a side perspective view of yet another embodiment of anextrusion-coated structural system including at least oneextrusion-coated structural member with a reinforced region;

FIG. 7 is a side perspective view of one embodiment of anextrusion-coated structural system including multiple extrusion-coatedstructural members coupled to one another by a plurality of hardwaremembers;

FIG. 8 is a side perspective view of another embodiment of anextrusion-coated structural system including multiple extrusion-coatedstructural members coupled by a plurality of hardware members;

FIG. 9 is a side perspective view of one embodiment of anextrusion-coated structural system including at least oneextrusion-coated structural member having a structural recess and ahardware protrusion;

FIG. 10 is another side perspective view of the extrusion-coatedstructural system depicted in FIG. 9;

FIG. 11 is a schematic cross-section of the extrusion-coated structuralsystem depicted in FIGS. 9 and 10;

FIG. 12 is a partial perspective view of an extrusion-coated structuralsystem configured according to one embodiment of the present invention,particularly illustrating an integrated hinge;

FIG. 13 is a partial front perspective view of an extrusion-coatedstructural system configured according to another embodiment of thepresent invention, particularly illustrating an integrated drawerroller;

FIG. 14 is the a partial rear perspective view of the extrusion-coatedstructural system depicted in FIG. 13;

FIG. 15 is a side perspective view of an extrusion-coated structuralsystem configured according to still another embodiment of the presentinvention, particularly illustrating an integrated shelf support in aunlocked configuration;

FIG. 16 is another side perspective view of the extrusion-coatedstructural system depicted in FIG. 15, with the extrusion-coatedstructural member in a locked configuration;

FIG. 17 is a side perspective view of an extrusion-coated structuralsystem configured according to still another embodiment of the presentinvention, particularly illustrating an integrated hinge;

FIG. 18 is a side perspective view of the extrusion-coated structuralsystem illustrated in FIG. 17;

FIG. 19 is a magnified schematic cross-sectional view of the connectingregion between the hardware protrusion and structural recess of theextrusion-coated structural system shown in FIGS. 17 and 18;

FIG. 20 is a side view of another embodiment of an extrusion-coatedstructural system including an integrated hinge;

FIG. 21 is a magnified schematic cross-sectional view of the connectingregion between the hardware recess and structural protrusion of theextrusion-coated structural system shown in FIG. 20;

FIG. 22 is a side perspective view of one embodiment of extrusion-coatedstructural system comprising a pair of extrusion-coated structuralmembers;

FIG. 23 is a schematic cross-sectional view of the extrusion-coatedstructural system depicted in FIG. 22;

FIG. 24 is a side perspective view of one embodiment of anextrusion-coated structural system comprising a plurality of snap-onpanels having both a protrusion and a recess;

FIG. 25 is a side perspective view of another embodiment of anextrusion-coated structural system, arranged in a disassembledconfiguration;

FIG. 26 is a side perspective view of the extrusion-coated structuralsystem depicted in FIG. 25, with the panels arranged in an assembledconfiguration;

FIG. 27 is a side perspective view of another embodiment of anextrusion-coated structural system, arranged in a disassembledconfiguration;

FIG. 28 is a side perspective view of the extrusion-coated structuralsystem depicted in FIG. 27, arranged in an assembled configuration;

FIG. 29 is a side perspective view of another embodiment of anextrusion-coated structural system, arranged in a disassembledconfiguration;

FIG. 30 is a side perspective view of the extrusion-coated structuralsystem depicted in FIG. 29, arranged in an assembled configuration;

FIG. 31 is a side perspective view of one embodiment of anextrusion-coated structural member having an extruded profile member;

FIG. 32 is a schematic cross-sectional view of the extrusion-coatedstructural member depicted in FIG. 31;

FIG. 33 is a bottom perspective view of another embodiment of anextrusion-coated structural system having an extruded profile member;

FIG. 34 is side perspective view of the extrusion-coated structuralsystem depicted in FIG. 33;

FIG. 35 is an end perspective view of one embodiment of anextrusion-coated structural system having an extrusion-coated structuralmember including a functional or aesthetic element;

FIG. 36 is a side perspective view of the extrusion-coated structuralsystem depicted in FIG. 35;

FIG. 37 is a side perspective view of one embodiment of anextrusion-coated structural system having a bridging member;

FIG. 38 is a break-away perspective view of the extrusion-coatedstructural system shown in FIG. 37;

FIG. 39 is side perspective view of another embodiment of anextrusion-coated structural system comprising a bridging member,arranged in a flat configuration;

FIG. 40 is a side perspective view of the extrusion-coated structuralsystem depicted in FIG. 39, arranged in a folded configuration;

FIG. 41 is a side perspective view of the extrusion-coated structuralsystem depicted in FIGS. 39 and 40, arranged in another foldedconfiguration;

FIG. 42 is side perspective view of yet another embodiment of anextrusion-coated structural system comprising a bridging member,arranged in a flat configuration;

FIG. 43 is a side perspective view of the extrusion-coated structuralsystem depicted in FIG. 42, arranged in a folded configuration;

FIG. 44 is a side perspective view of the extrusion-coated structuralsystem depicted in FIGS. 42 and 43, also including a securing member;

FIG. 45 is a side perspective view of one embodiment of anextrusion-coated structural system, arranged in a flat configuration;

FIG. 46 is a side perspective view of the extrusion-coated structuralsystem shown in FIG. 45, arranged in a folded configuration;

FIG. 47 is a top perspective view of another embodiment of anextrusion-coated structural system, arranged in a flat configuration;

FIG. 48 is a side perspective view of the extrusion-coated structuralsystem shown in FIG. 47;

FIG. 49 is a side perspective view of the extrusion-coated structuralsystem shown in FIGS. 47 and 48, arranged in a folded configuration;

FIG. 50 is a side perspective view of yet another embodiment of anextrusion-coated structural system, arranged in a flat configuration;

FIG. 51 is a side perspective view of the extrusion-coated structuralsystem shown in FIG. 50, arranged in a folded configuration;

FIG. 52 is a side perspective view of still another embodiment of anextrusion-coated structural system, arranged in a compressedconfiguration;

FIG. 53 is a side perspective view of the extrusion-coated structuralsystem shown in FIG. 52, arranged in an extended configuration;

FIG. 54 is a side perspective view of a further embodiment of anextrusion-coated structural system, arranged in a flat configuration;

FIG. 55 is a side perspective view of the extrusion-coated structuralsystem shown in FIG. 54, arranged in an a folded configuration;

FIG. 56 is a side perspective view of the extrusion-coated structuralsystem shown in FIGS. 54 and 55, arranged in an another foldedconfiguration;

FIG. 57 is a side perspective view of another embodiment of anextrusion-coated structural system, arranged in a flat configuration;

FIG. 58 is a side perspective view of the extrusion-coated structuralsystem shown in FIG. 57, arranged in an a folded configuration;

FIG. 59 is a side perspective view of the extrusion-coated structuralsystem shown in FIGS. 57 and 58, arranged in an another foldedconfiguration;

FIG. 60 is a schematic diagram of the major steps in a process formaking an extrusion-coated structural member according to one embodimentof the present invention;

FIG. 61 is a side perspective view of one embodiment of anextrusion-coated structural system comprising a pair of extrusion-coatedstructural members;

FIG. 62 is a schematic cross-sectional view of the extrusion-coatedstructural system depicted in FIG. 61;

FIG. 63 is a schematic cross-sectional view of the substrate componentsof the extrusion-coated structural members depicted in FIGS. 61 and 62,depicted without coating material;

FIG. 64 is a schematic cross-sectional view of one embodiment of asubstrate subjected to strength testing as described in Example 3; and

FIG. 65a is a side view of the flush configuration used to strength testa substrate as described in Example 3;

FIG. 65b is a side view of the half configuration used to strength testa substrate as described in Example 3; and

FIG. 65c is a side view of the outer configuration used to strength testa substrate as described in Example 3.

DETAILED DESCRIPTION

In one aspect, the present invention relates to extrusion-coatedstructural member and structural systems employing such structuralmembers, as well as methods for making and using the same.Extrusion-coated structural systems configured according to embodimentsof the present invention, can be more durable, easier to assemble, andprovide enhanced aesthetic appearance over similar, conventionally-madearticles. Additionally, structural systems of the present invention maybe easier and/or less expensive to manufacture and/or ship, making thesesystems beneficial both for manufacturers and end users. Structuralsystems according to the present invention may be used in a variety ofinterior and exterior applications including, for example, as componentsof furniture or cabinetry, or as building materials such as flooring,wall covering, trim, molding, and the like.

In one embodiment, the extrusion-coated structural system can include atleast one extrusion-coated structural member comprising at least onesubstrate and a coating material extrusion coated onto at least aportion of the substrate. As used herein, the term “extrusion coated”refers to a substrate which has been coated, or at least partiallycoated, with a coating material via an extrusion coating process.Extrusion coating can also include forming at least one extruded profilemember spaced apart and extending outwardly from the substrate. Specificembodiments of extrusion-coated structural members including extrudedprofile members will be discussed in detail shortly. The coatingmaterial applied via extrusion coating may comprise a resin and can beapplied under pressure and/or at an elevated temperature, althoughneither is required. In some embodiments, the coating material appliedvia extrusion coating may comprise at least one thermosetting and/orthermoplastic resin, optionally in combination with additionalcomponents. Examples of suitable coating materials and types ofsubstrates suitable for use in the extrusion-coated structural systemsof the present invention will be discussed in detail shortly.

In one embodiment, the extrusion-coated structural system can include atleast one extrusion-coated structural member having a reinforced region.As used herein, the term “reinforced region” refers to an area of astructural member having increased strength and/or flexibility ascompared to another area of the structural member. In one embodiment,the reinforced region or regions of the structural member may include acoating material applied with a greater thickness than the coatingmaterial applied to other regions of the substrate. For example, in oneembodiment, the average thickness of the coating material applied to thereinforced region of the structural member can be at least about 2, atleast about 3, at least about 4, at least about 5, at least about 10times greater than the average thickness of the coating material appliedto the remainder of the structural member. In some cases, the averagethickness of the coating material in the reinforced region may be atleast about 2, at least about 3, at least about 4, at least about 5, orat least about 10 times greater than the average thickness of thecoating material applied to the substrate proximate the reinforcedregion. Additionally, or in the alternative, the maximum thickness ofthe coating material applied to the reinforced region may be at leastabout 2, at least about 3, at least about 5, at least about 10 timesgreater than the maximum thickness of the coating material applied tothe remainder of the substrate and/or the average thickness of thecoating material applied to the substrate proximate the reinforcedregion. The coating material applied to the reinforced region may be thesame as, or different than, the coating material applied to the rest ofthe structural member.

Turning now to FIGS. 1-3, several embodiments of extrusion-coatedstructural members including at least one reinforced region areprovided. Turning first to FIG. 1, one embodiment of an extrusion-coatedstructural member 10 that includes at least one reinforced region 12 isshown. As shown in FIG. 1, structural member 10 comprises at least onesubstrate 14 and a coating material 16 coated onto at least a portion ofsubstrate 14. Preferably, coating material 16 has been extrusion coatedonto substrate 14. Reinforced region 12 of structural member 10 is shownas including at least one structural recess 18 extending inwardly froman outer surface 20 a of substrate 14. A coating material 22 extrusioncan have been extrusion coated onto at least a portion of structuralrecess 18 or, alternatively, the coating may have been applied inanother manner, such as, for example, via brushing, spraying, and/ordipping. Coating material 22 can be the same as, or different than,coating material 16 coated onto the outer surfaces 20 a-d of substrate14.

The average thickness of coating material 22, measured from the uppersurface 26 of coating material 22 to the bottom 28 of recess 18, may begreater than the average thickness of coating material 16 applied to anear-recess external surface 24 of substrate 14. For example, in oneembodiment, the average thickness of coating material 22 withinstructural recess 18 can be at least about 1.5, at least about 2, atleast about 5 times thicker than the average thickness of coatingmaterial 16 applied to near-recess external surface 24. Additionally,the maximum thickness of coating material 22 within structural recess 18can be at least about 2, at least about 3, at least about 5, at leastabout 10 times and/or not more than about 100, not more than about 50,not more than about 25, not more than about 15 times greater than themaximum thickness of coating material 16 applied to near-recess externalsurface 24 and/or than the average thickness of coating material 16applied to the at least a portion of surfaces 20 a-d of substrate 14.

In one embodiment, the maximum thickness of coating material 22 withinstructural recess 18 can be in the range of from about 1.5 to about 100,about 1.5 to about 50, about 1.5 to about 25, about 1.5 to about 15,about 2 to about 100, about 2 to about 50, about 2 to about 25, about 2to about 15, about 3 to about 100, about 3 to about 50, about 3 to about25, about 3 to about 15, about 5 to about 100, about 5 to about 50,about 5 to about 25, about 5 to about 15, about 10 to about 100, about10 to about 50, about 10 to about 25, about 10 to about 15 times greaterthan the maximum thickness of coating material 16 applied to near-recessexternal surface 24 and/or than the average thickness of coatingmaterial 16 applied to the at least a portion of surfaces 20 a-d ofsubstrate 14.

The average thickness of coating material 16 coated onto surfaces 20 a-dand/or near-recess external surface 24 of substrate 14 can be at leastabout 0.001, at least about 0.005, at least about 0.010 inches and/ornot more than about 0.025, not more than about 0.020, not more thanabout 0.015 inches, or in the range of from about 0.001 to about 0.025inches, about 0.001 to about 0.020 inches, about 0.001 to about 0.015inches, about 0.005 to about 0.025 inches, about 0.005 to about 0.020inches, about 0.025 to about 0.015 inches, about 0.010 to about 0.025inches, about 0.010 to about 0.020 inches, about 0.010 to about 0.015inches. The average thickness of coating material 22 disposed withinrecess 18 can be at least about 0.001 inches, at least about 0.005inches, at least about 0.01 inches, at least about 0.02 inches and/ornot more than about 0.50 inches, not more than about 0.25 inches, notmore than about 0.10 inches, not more than about 0.05 inches, dependingon the specific configuration of the structural member. The averagethickness of average thickness of coating material 22 disposed withinrecess 18 can be in the range of from about 0.001 to about 0.50 inches,about 0.001 to about 0.25 inches, about 0.001 to about 0.10 inches,about 0.001 to about 0.05 inches, about 0.005 to about 0.50 inches,about 0.005 to about 0.25 inches, about 0.005 to about 0.10 inches,about 0.005 to about 0.05 inches, about 0.01 to about 0.50 inches, about0.01 to about 0.25 inches, about 0.01 to about 0.10 inches, about 0.01to about 0.05 inches, about 0.02 to about 0.50 inches, about 0.02 toabout 0.25 inches, about 0.02 to about 0.10 inches, about 0.02 to about0.05 inches.

In one embodiment, structural recess 18 can be at least partially, orentirely, filled with coating material 22. For example, in oneembodiment, at least about 40 percent, at least about 50 percent, atleast about 60 percent, at least about 75 percent, at least about 80percent, or at least about 90 percent of at least one lateralcross-section of structural recess 18 can be filled with coatingmaterial 22. In the same or another embodiment, at least about 40percent, at least about 50 percent, at least about 60 percent, at leastabout 75 percent, at least about 80 percent, or at least about 90percent, at least about 95 percent of the total volume of structuralrecess 18 can be filled with coating material 22. In one embodiment,coating material 22 can fill structural recess 18 beyond the inlet ofstructural recess 18 defined by substrate 14, such that the uppermostsurface 26 of coating material 22 applied to structural recess 18 can becontinuous with coating material 16 coated onto near-recess externalsurface 24, as shown in the embodiments depicted in FIGS. 1-3.

Extrusion-coated structural member 10 can include any suitable number ofstructural recesses 18. In one embodiment depicted in FIG. 1,extrusion-coated structural member 10 can include a single structuralrecess 18, while in another embodiment, examples of which are shown inFIGS. 2 and 3, extrusion-coated structural member 10 can include aplurality of structural recess 18 extending from one or more outersurfaces 20 of substrate 14. In one embodiment, structural member 10 caninclude at least 2, at least 4, at least 5 and/or not more than 20, notmore than 15, not more than 10 recesses, or can include about 2 to about20, about 4 to about 15, or about 5 to about 10 recesses extending fromone or more surfaces 20 of substrate 14. When substrate 14 includes morethan one recess 18, the structural recesses may have the same size,shape, and/or be coated with the same type of coating material, or atleast one of the size, shape, and/or coating material applied to one ormore of structural recesses 18 may be different than the size, shape,and/or coating material applied to one or more of the other ofstructural recesses 18.

When structural member 10 includes more than one structural recess, allor a portion of the recesses may extend from the same surface and/or oneor more recesses may extend from a different surface than one or moreother recesses. When one or more recesses extend from differentsurfaces, the surfaces may be adjacent surfaces, such as, for example,surfaces 20 a and 20 b in FIG. 3. Alternative, the different surfacesfrom which the recesses extend may be opposite surfaces, such as, forexample, surfaces 20 a and 20 c shown in FIG. 2. When at least a portionof the recesses extend from opposite surfaces, the recesses can bearranged in a staggered configuration, as shown in FIG. 2, or at least aportion of the recesses 18 can be directly opposed from one another. Thespacing between adjacent structural recesses 18 extending from a singlesurface 20 a-d can be at least about 5 percent, at least about 10percent, at least about 20 percent and/or not more than 50 percent, notmore than about 40 percent, not more than about 30 percent of the totallength of the surface 20 a-d from which the recesses 18 extend. Thespacing between adjacent structural recesses 18 extending from a singlesurface 20 a-d can be in the range of from about 5 to about 50 percent,about 5 to about 40 percent, about 5 to about 30 percent, about 10 toabout 50 percent, about 10 to about 40 percent, about 10 to about 30percent, about 20 to about 50 percent, about 20 to about 40 percent,about 20 to about 30 percent.

In one embodiment, the ratio of the depth (d_(r)) of structural recess18 to the dimension of substrate 14 parallel to the depth of structuralrecess 18 can be at least about 0.10:1, at least about 0.25:1, at leastabout 0.50:1 and/or not more than about 0.99:1, not more than about0.90:1, not more than about 0.85:1, or in the range of from about 0.10:1to about 0.99:1, about 0.10:1 to about 0.90:1, about 0.10:1 to about0.85:1, about 0.25:1 to about 0.99:1, about 0.25:1 to about 0.90:1,about 0.25:1 to about 0.85:1, about 0.50:1 to about 0.99:1, about 0.50:1to about 0.90:1, about 0.50:1 to about 0.85:1. As used herein, the“depth” of a structural recess is defined as the distance that thestructural recess extends into the substrate. For example, as shown inthe embodiment depicted in FIG. 1, when structural recess 18 ofextrusion-coated structural member 10 extends inwardly from surface 20a, which defines the thickness (T) or shortest dimension of substrate14, the depth (d_(r)) of structural recess 18 is parallel to surfaces 20b and 20 d, which are illustrated in FIG. 1 as defining the width (W),or second longest dimension, of the substrate 14. Thus, in thisembodiment, the ratio of the depth (d_(r)) of structural recess 18 tothe width of substrate 14 can fall within the ranges described above.

Alternatively, according to another embodiment depicted in FIG. 2, ifstructural recess 18 extends from a surface 20 a that defines the width(W) of substrate 14, the depth (d_(r)) of the structural recess 18 isparallel to the thickness (T) of substrate 14. Thus, in this embodiment,the ratio of the depth (d_(r)) of structural recess 18 to the thicknessof substrate 14 may fall within one or more ranges described above. Infurther embodiments (not shown in FIGS. 1 and 2), the structural recessof the structural member may extend through the entire width orthickness of the structural member such that the ratio of the depth ofthe recess to the dimension of the substrate parallel to the depth ofthe structural recess can be about 1:1.

Similarly, the “width” of the structural recess (w_(r)) refers to thedimension of the structural recess parallel to the surface from whichthe structural recess extends. For example, as shown in the embodimentin FIG. 1, if the structural recess 18 extends from an outer surface 20a of substrate 14 that defines the thickness (T) of substrate 14, thewidth (w_(r)) of structural recess 18 may be parallel to the thickness(T) of substrate 14. Alternatively, as shown in the embodiment depictedin FIG. 2, if the structural recess 18 extends from an outer surface 20a of substrate 14 that defines the width (W) of substrate 14, the width(w_(r)) of structural recess 18 can be parallel to the width (W) ofsubstrate 14. The ratio of the width of the structural recess to thedimension of the substrate parallel to the width of the structuralrecess can be at least about 0.005:1, at least about 0.010:1, at leastabout 0.025:1 and/or not more than about 0.2:1, not more than about0.10:1, not more than about 0.05:1, or ratio of the width of thestructural recess to the dimension of the substrate parallel to thewidth of the structural recess can be in the range of from about 0.005:1to about 0.2:1, about 0.005:1 to about 0.1:1, about 0.005:1 to about0.05:1, about 0.010:1 to about 0.2:1, about 0.010:1 to about 0.1:1,about 0.010:1 to about 0.05:1, about 0.025:1 to about 0.2:1, about0.025:1 to about 0.1:1, about 0.025:1 to about 0.05:1.

In one embodiment, the width and/or depth of the structural recess canbe substantially constant, while, in another embodiment, one or bothrecess dimensions may change along the length of the recess. Accordingto one embodiment, the ratio of the maximum width of the structuralrecess (w_(r)) to its maximum depth (d_(r)) can be at least about0.001:1, at least about 0.01:1, at least about 0.05:1, at least about0.10:1, at least about 0.50:1, at least about 1:1 and/or not more thanabout 5:1, not more than about 4:1, not more than about 2:1, not morethan about 1:1, not more than about 0.50:1, not more than about 0.25:1,not more than about 0.10:1.

The ratio of the maximum width of the structural recess (w_(r)) to itsmaximum depth (d_(r)) can be in the range of from about 0.001:1 to about5:1, about 0.001:1 to about 4:1, about 0.001:1 to about 2:1, about0.001:1 to about 1:1, about 0.001:1 to about 0.5:1, about 0.001:1 toabout 0.25:1, about 0.001:1 to about 0.10:1, about 0.01:1 to about 5:1,about 0.01:1 to about 4:1, about 0.01:1 to about 2:1, about 0.01:1 toabout 1:1, about 0.01:1 to about 0.5:1, about 0.01:1 to about 0.25:1,about 0.01:1 to about 0.10:1, about 0.05:1 to about 5:1, about 0.05:1 toabout 4:1, about 0.05:1 to about 2:1, about 0.05:1 to about 1:1, about0.05:1 to about 0.5:1, about 0.05:1 to about 0.25:1, about 0.05:1 toabout 0.10:1, about 0.1:1 to about 5:1, about 0.1:1 to about 4:1, about0.1:1 to about 2:1, about 0.1:1 to about 1:1, about 0.1:1 to about0.5:1, about 0.1:1 to about 0.25:1, about 0.5:1 to about 5:1, about0.5:1 to about 4:1, about 0.5:1 to about 2:1, about 0.5:1 to about 1:1,about 1:1 to about 5:1, about 1:1 to about 4:1, about 1:1 to about 2:1.

The structural recess may extend along at least a portion of the length,or longest dimension, of the structural member. In one embodiment, thestructural recess may be an elongated recess and can extend along aportion of the length of the structural member such that the ratio ofthe length of the structural recess (not shown in FIGS. 1 and 2) to thelength of the structural member (L) can be at least 0.50:1, at leastabout 0.60:1, at least about 0.75:1, at least about 0.85:1, at leastabout 0.90:1 and/or not more than about 1:1, not more than about 0.95:1,not more than about 0.90:1. The structural recess may extend along atleast about 50 percent, at least about 60 percent, at least about 70percent, at least about 80 percent, or at least about 90 percent of thetotal length of the substrate.

The ratio of the length of the structural recess to the length of thestructural member (L) can be in the range of from about 0.50:1 to about1:1, about 0.50:1 to about 0.95:1, about 0.50:1 to about 0.90:1, about0.60:1 to about 1:1, about 0.60:1 to about 0.95:1, about 0.60:1 to about0.90:1, about 0.75:1 to about 1:1, about 0.75:1 to about 0.95:1, about0.75:1 to about 0.90:1, about 0.85:1 to about 1:1, about 0.85:1 to about0.95:1, about 0.85:1 to about 0.90:1, about 0.90:1 to about 1:1, about0.90:1 to about 0.95:1.

In another embodiment, the structural recess may not be an elongatedslot and can be, for example, a shortened slot or a hole. According tothis embodiment, the ratio of the length of the structural recess to thelength of the structural member can be no more than about 0.50:1, notmore than about 0.40:1, not more than about 0.30:1, not more than about0.20:1, not more than about 0.10:1. The structural recess may extendalong not more than about 50 percent, not more than about 40 percent,not more than about 30 percent, not more than about 20 percent, not morethan about 10 percent of the total length of the substrate.Additionally, the ratio of the length of the structural recess to itsmaximum width can be at least about 0.25:1, at least about 0.50:1, atleast about 0.75:1 and/or not more than about 1.5:1, not more than about1.1:1, not more than about 0.90:1, or in the range of from about 0.25:1to about 1.5:1, about 0.25:1, to about 1.1:1, about 0.25:1 to about0.90:1, about 0.50:1 to about 1.5:1, about 0.50:1, to about 1.1:1, about0.50:1 to about 0.90:1, about 0.75:1 to about 1.5:1, about 0.75:1, toabout 1.1:1, about 0.75:1 to about 0.90:1.

Although shown in FIGS. 1-3 as being formed within a single substrate,the structural recess may also be collectively defined by two or moresubstrates positioned proximate one another. The structural recess canhave any suitable cross-sectional shape, such as, for example, a squareshape, a rectangular shape, a semi-circular shape, a triangular shape,or other polygonal shape.

Extrusion-coated structural systems configured according to the presentinvention can include one or more extrusion-coated structural members 10as described above. For example, in one embodiment depicted in FIG. 4,extrusion-coated structural system 110 can include a pair ofextrusion-coated structural members 112 a, b, which each include asubstrate 114 a, b and a coating material 116 a, b extrusion coated ontoat least a portion of substrate 114 a, b. As shown in the embodiment inFIG. 4, each of structural members 112 a and 112 b can include areinforced region 113 a, 113 b positioned proximate to the locationwhere structural members 112 a,b are joined. In another embodiment (notshown), only one of substrates 112 a or 112 b may include a reinforcedregion 113. Each of reinforced regions 113 a,b include one or aplurality of structural recesses 118 extending inwardly from at leastone surface 120 a, 120 b of substrates 114 a,b. Structural recesses 118may be coated with a coating material having a thickness greater thanthe coating material coated onto substrate 114 a,b proximate recesses118 and/or may be further configured according to one or moreembodiments described previously with respect to FIGS. 1-3.

Extrusion-coated structural systems configured according to embodimentsof the present invention may also include one or more additionalcomponents such as, for example, one or more hardware components.Turning now to FIGS. 5-7, several examples of extrusion-coatedstructural systems that include at least one extrusion-coated structuralmember and at least one hardware component are provided. Referring firstto FIG. 5, an extrusion-coated structural member 150 is illustrated asgenerally comprising a substrate 152 and a coating material 154extrusion-coated on to at least a portion of substrate 152. In theembodiment shown in FIG. 5, coating material 154 has been applied to atleast about 90 percent, at least about 95 percent, at least about 99percent, or all of the outer surfaces 170 a-d of substrate 152.

Additionally, extrusion-coated structural member 150 comprises astructural recess 156 extending inwardly from outer surface 170 a ofsubstrate 152 and at least one near-recess external surface 158 a or 158b proximate recess 156. Structural recess 156 is at least partiallycoated with a coating material, which can be the same as or differentthan, coating material 154 applied to one or both of near-recessexternal surfaces 158 a,b. In the embodiment shown in FIG. 5, thecoating material is continuous with at least a portion of coatingmaterial 154 applied to near-recess external surfaces 158 a and/or 158b.

As depicted in the embodiment shown in FIG. 5, structural recess 156 ofstructural member 150 is an elongated recess having a cross-sectionalshape that remains substantially constant along its length. Structuralrecess 156 can include a broad portion 160 and a narrow portion 162,with narrow portion 162 being closer to near-recess external surface158. Structural recess 156 also presents a recess attachment surface166, which can be at least partially defined by coating material. Recessattachment surface 166, which extends generally between near-recessexternal surfaces 158 a, b, can be configured to receive at least aportion of a hardware component 168, illustrated in FIG. 5 as a screw,so that, when inserted into structural recess 156, at least a portion ofhardware member 168 can be at least partially supported by recessattachment surface 166.

As used herein, the term “hardware member” refers to any componentseparate from the structural member used to enhance the functionality,strength, and/or aesthetic characteristics of the structural member orsystem. Examples of hardware members can include, but are not limitedto, screws, bolts, nuts, slides, rollers, handles, pins, and supports.However, in one embodiment, the hardware members included in structuralsystems of the present invention can also include other substrates, orportions of thereof, such as, for example, boards, shelves, trim, andother similar components. In another embodiment, the hardware member maybe defined by one or more other extrusion-coated structural membersand/or itself may be an extrusion-coated structural member. Whenconfigured for insertion into a structural recess, such as structuralrecess 156, hardware member 168 may include at least one hardwareprotrusion 172. Hardware protrusion 172 can be of any suitable sizeand/or shape, and may be threaded, as illustrated in the embodimentshown in FIG. 5.

When hardware protrusion 172 is inserted into structural recess 156, atleast a portion of recess attachment surface 166 may be configuredsupport hardware protrusion 172. As used herein, the term “support”means to restrict or prevent motion in at least one direction.Structural recess 156 of structural member 150 may be configured suchthat hardware protrusion 172 directly contacts at least a portion ofrecess attachment surface 166, or recess attachment surface 166 caninclude at least one layer of intervening material (not shown in FIG. 5)disposed between at least a portion of recess attachment surface 166 andhardware protrusion 172.

When present, the intervening material layer can be made of any suitablematerial and may comprise one or more materials different than coatingmaterial 154 applied to near-recess external surface 158. Theintervening material layer can add functionality to the recess and/ormay improve its aesthetic characteristics or durability. In oneembodiment, the intervening material layer can be a friction-modifyinglayer to either enhance or reduce the friction between recess attachmentsurface 166 and hardware protrusion 172. In one embodiment, theintervening material layer can be a friction enhancing layer capable ofincreasing the friction between recess attachment surface 166 andhardware protrusion 172 by at least about 5 percent, at least about 10percent, or at least about 15 percent and may be, for example, a coatingmaterial comprising a medium or coarse grit of a layer or sand paper. Inanother embodiment, the intervening material layer can be afriction-reducing layer configured to reduce the friction between recessattachment surface 166 and hardware protrusion 172 by at least about 5,at least about 10, at least about 15 percent. Suitable materials forinclusion in the friction-reducing intervening layer can include, forexample, TEFLON® or other similar materials.

When structural recess is at least partially coated with coatingmaterial 159, the withdrawal force required to remove hardwareprotrusion 172 from structural recess 156 may be higher than if thecoating material were not present. For example, in one embodiment, thewithdrawal force required to remove hardware protrusion 172 fromstructural recess 156, once inserted, may be at least about 300 pounds,at least about 350 pounds, at least about 400 pounds, at least about 450pounds, at least about 475 pounds, at least about 500 pounds, measuredaccording to ASTM D1037 and as further described in Example 1. Incontrast, the withdrawal force required to remove the same hardwarecomponent from a similarly-configured but uncoated structural recess maybe less than about 300 pounds. Extrusion-coated structural member 150may be useful in furniture or cabinetry applications, for example,wherein increased withdrawal strength may be beneficial to increase thedurability of the structural system.

Turning now to FIG. 6, another embodiment of an extrusion-coatedstructural system 200 including an extrusion-coated structural member210 is provided. In the embodiment shown in FIG. 6, the extrusion-coatedstructural member 210 includes a substrate 212 and a coating material214 coated onto at least a portion of the substrate 212. Substrate 212is also illustrated as comprising plurality of structural recesses,including an elongated slot 216 and a plurality of holes 218, each atleast partially filled with the coating material 214. Extrusion-coatedstructural system 210 further includes a plurality of hardware members220 a-d, shown in FIG. 6 as a plurality of screws, each comprising ahardware protrusion 222 a-d configured for insertion into at least one,or both, of structural recesses 216, 218.

Elongated slot 216 can extend along at least a portion of the length ofextrusion-coated structural member 210 and, in one embodiment, maypresent a recess attachment surface 224 that may optionally be threaded.Each of hardware protrusions 222 a-d of hardware members 220 a-d can beconfigured for insertion into elongated slot 216, and, in oneembodiment, may be configured for insertion at multiple locations alongthe length of elongated slot 216. Additionally, in one embodiment, twoor more hardware protrusions, such as, for example, protrusions 222 a, bshown in FIG. 6, may be configured for simultaneous insertion intoelongated slot 216, such that two or more hardware protrusions 222 a, bmay be at least partially supported by recess attachment surface 224.Although not shown in FIG. 6, at least a portion of recess attachmentsurface 224 may include at least one intervening material layer.

Additionally, as shown in the embodiment depicted in FIG. 6,extrusion-coated structural member 210 can include a plurality of holes218 each extending inwardly from an outer surface. As shown in FIG. 6,at least a portion (or all) of holes 218 may be at least partially, orentirely, filled with coating material 214. The hardware protrusion 222a-d of each of hardware members 220 a-d may be configured for insertioninto one or more of holes 218 and, as shown in FIG. 6, two or morehardware protrusion 222 c,d may be received into separate holes(structural recesses) 218 at the same time. Extrusion-coated structuralsystem 210 may be useful in furniture or cabinetry applications when itmay be advantageous to adjust the position of the hardware member, suchas, for example, in shelving or cabinetry applications.

Turning now to FIG. 7, one embodiment of an extrusion-coated structuralsystem 250 comprising more than one extrusion-coated structural members252 a-c and a plurality of hardware members 266 a-d is provided. In theembodiment depicted in FIG. 7, extrusion-coated structural system 250includes at least three extrusion-coated structural members 252 a-c thateach includes a substrate 254 a-c and a coating material 256 a-cextrusion coated onto to at least a portion of each substrate 254 a-c.Each of substrates 254 a and 254 b comprise a pair of structuralrecesses 253 a, b and 255 a, b spaced apart from one another along thewidth of substrates 254 a, b. In the embodiment shown in FIG. 7, each ofstructural recesses 253 a,b and 255 a,b comprise elongated slotsextending along at least a portion of the length of substrates 254 a,bthat are at least partially filled with coating material 256. Each ofslots 253 a, b and 255 a, b present a respective recess attachmentsurface 258 a, b and 260 a, b (260 a not shown) formed of the coatingmaterial. Additionally, each of recesses 253 a, b and 255 a, b include arecess inlet 257 a, b and 259 a, b (259 a not shown) defined by an outersurface 262 a, b of substrate 254 a, b. Although shown as being uncoatedin FIG. 7, outer surfaces 262 a,b of substrates 254 a,b may also be atleast partially coated with coating material 256 a,b.

Additionally, as shown in FIG. 7, substrate 254 c includes fourstructural recesses 262 a-d spaced apart from one another and extendingthrough the entire thickness of substrate 254 c. Each of structuralrecesses 262 a-d are at least partially coated with coating material 256c and may present at least one recess attachment surface 264 a-d definedby coating material 256 c. Alternatively, structural recesses 262 a-dmay be formed in extrusion coated member 252 c after substrate 254 c hasbeen extrusion coated and, in that embodiment, structural recesses 262a-d may not be coated with a coating material.

Extrusion-coated structural system 250 further comprises four hardwaremembers, shown as screws 266 a-d, each comprising a hardware protrusion268 a-d, shown in FIG. 7 as being threaded hardware protrusions. Asshown in FIG. 7, each of hardware protrusions 268 a-d of hardwaremembers 266 a-d are configured for insertion into respective recessinlets 257 a,b and 259 a,b (259 a not shown) via structural recess 262a-b of substrate 254 c. Once inserted, a portion of hardware protrusion268 a, for example, can be at least partially supported by recessattachment surface 264 a of structural recess 262 a and recessattachment surface 258 a of elongated recess 253 a of substrate 254 a.If structural recess 262 a is not coated with coating material 256, thehardware protrusion 268 a can be at least partially supported, or indirect contact with, a surface of structural recess 262 a. Similarly,hardware protrusions 268 b-d inserted into and through respectivestructural recesses 262 b-d can be received into inlets 257 b and 259 a(not shown) and 259 b of elongated recesses 253 b and 255 a, b. Onceinserted, a portion of hardware protrusions 268 b-d may be at leastpartially supported by respective recess attachment surfaces 264 b-d (ora surface 262 b-d of structural recesses 262 b-d if uncoated) and recessattachment surfaces 258 b, 260 a (not shown), and 260 b.

Turning now to FIG. 8, another embodiment of an extrusion-coatedstructural system 300 is illustrated as generally comprising a pair ofextrusion-coated structural members 312, 314, and two hardware members316 a, b. As shown in FIG. 8, each of extrusion-coated structuralmembers 312, 314 comprises a substrate 318, 320 and a coating material322, 324 extrusion-coated onto at least a portion of respectivesubstrates 318, 320. Coating materials 322 and 324 may be the same ordifferent. As shown in the embodiment depicted in FIG. 8, substrate 318comprises a single structural recess 326, while substrate 320 comprisestwo structural recesses 328 and 330. Structural recesses 326 and 328each include a respective inlet 325 a, b and an outlet (not shown) andextend through the entire thickness respective substrates 318 and 320.Structural recess 330 includes a recess inlet 338 defined on an outersurface 336 of substrate 320. As shown in FIG. 8, structural recess 330is at least partially coated by coating material 324 and presents arecess attachment surface 332 at least partially formed of the coatingmaterial.

Extrusion-coated structural system 300 further comprises two hardwaremembers, shown in FIG. 8 as a bolt 316 a and a nut 316 b, configured forinsertion into one or more of structural recesses 326, 328, 330 ofstructural members 312, 314. As shown in the embodiment depicted in FIG.8, bolt 316 a, which comprises a hardware protrusion 344, can beconfigured for insertion into and through structural recesses 326 and328 so that at least a portion of structural recesses 326 and 328 can atleast partially support hardware protrusion 344. In one embodiment, atleast a portion of one or both of structural recesses 326 and 328 may becoated by coating material 322 or 324 and, in those cases, at least aportion of hardware protrusion 344 may be supported by at least onerecess attachment surface (not shown) formed of coating material 322 or324. Simultaneously, nut 342 may also be inserted into broad portion 334of structural recess 330 via recess inlet 338 and coupled with hardwareprotrusion 344 of bolt 316 a within structural recess 330. In thismanner, extrusion-coated structural members 312 and 314 may be coupledto one another while visually shielding nut 316 b and protrusion 344 ofbolt 316 a from view within recess 330, thereby enhancing the aestheticsof the entire system 300.

When the extrusion-coated structural system of the present inventionincludes at least one hardware member insertable into a structuralrecess, at least a portion of the hardware member can be configured formovement within the recess, once inserted. For example, in oneembodiment when the recess is an elongated recess, the hardware member,or portion thereof, may be configured to move in said recess in thedirection of elongation of said recess. Alternatively, the hardwareprotrusion may be movable in a direction substantially perpendicular tothe direction of elongation of the recess, while, in another embodiment,the hardware member or protrusion may be configured to rotate within thestructural recess. The movement of the hardware member within thestructural recess may be at least partially inhibited, either by atleast one locking mechanism which can selectively restrain the movementof the hardware protrusion within the recess, and/or by the physicaldimensions of the hardware protrusion and/or structural recess. Severalembodiments of extrusion-coated and hardware integrated systemscomprising a movable hardware protrusion are provided in FIGS. 9-19.

Turning initially to FIGS. 9-11, one embodiment of an extrusion-coatedstructural system 350 is provided. Extrusion-coated structural system350 illustrated in FIGS. 9-11 includes an extrusion-coated structuralmember 352 comprising a substrate 354 and a coating material 356extrusion coated to at least a portion of substrate 354. Substrate 354comprises a structural recess 358, which is at least partially coatedwith coating material 356. Structural recess 358 presents a recessattachment surface 360 configured to at least partially support ahardware member 362 when hardware member 362 is inserted into structuralrecess 358. In the embodiment shown in FIGS. 9-11, hardware member 362comprises a hardware protrusion, shown in FIGS. 9-11 as a pair ofmovable plates 364 a, b, disposed in a broad portion 368 of structuralrecess 358.

Hardware member 362 can further comprises a locking mechanism, shown asbolt or fastener 370, at least partially disposed in narrow portion 372of structural recess 358. Locking mechanism 370 can be a threadedmember, as particularly shown in FIG. 11, and may be configured forrotation to selectively permit and inhibit movement of one or both ofplates 364 a, b within structural recess 358. For example, as shown inFIGS. 9 and 10, rotation of locking mechanism 370, as indicated by arrow380, can cause upper plate 364 a of hardware member 362 to move in adirection generally perpendicular to the direction of extension ofrecess 358, as indicated by arrow 382 in FIG. 9. Opposite rotation oflocking mechanism 370, indicated by dashed arrow 384 in FIG. 10, maymove upper plate 364 a in the opposite direction.

Turning now to FIG. 12, another embodiment of an extrusion-coatedstructural system 400 is illustrated as generally comprising anextrusion-coated structural member 412 and a hardware member 420.Extrusion-coated structural member 412 comprises a substrate 414 and acoating material 416 extrusion coated onto at least a portion ofsubstrate 414. Structural member 412 comprises at least one structuralrecess 418, which is at least partially coated with coating material416, which presents a recess attachment surface 422 within structuralrecess 418. In one embodiment depicted in FIG. 12, at least a portion ofrecess attachment surface 422 may be formed by a portion of at least oneextruded profile member 424 formed of coating material 416 and extendingoutwardly from substrate 414. Additional embodiments of extrusion-coatedstructural members including extruded profile members will be discussedin detail shortly.

Hardware member 420, illustrated in FIG. 12 as comprising a hinge, maybe fastened to a second structural member 421, which may optionally beanother extrusion-coated structural member. Hardware member 420 cancomprise a hardware protrusion 428 having a narrow portion 430 and abroad portion 432. During assembly, broad portion 432 of hardware member420 may be inserted into broad section 436 of structural recess 418while narrow portion 430 of hardware member 420 can be inserted intonarrow section 434 of recess 418, such that hardware protrusion 428 maybe at least partially supported by a portion of recess attachmentsurface 422, which may optionally include at least one interveningmaterial layer disposed therein. Additionally, once inserted, hardwareprotrusion 428 may be configured for movement within recess 418 and,more particularly, may be configured for rotation within recess 418.When broad portion 432 of hardware protrusion 428 is wider than narrowsection 434 of structural recess 418, as shown in FIG. 12, removal ofhardware protrusion, once received in structural recess 418, isinhibited in at least one direction. In one embodiment, extrusion-coatedstructural system 400 may be a cabinet, structural member 421 may be acabinet box or support, and extrusion-coated structural member 412 canbe a cabinet door.

Another extrusion-coated structural system 450 configured according toone embodiment of the present invention is illustrated as generallycomprising an extrusion-coated structural member 452 and at least onehardware member 460. Extrusion-coated structural member 452, shown inFIGS. 13 and 14, as being a portion of a drawer or door, comprises asubstrate 454 and a coating material 456 extrusion-coated onto at leasta portion of substrate 454. Substrate 454 comprises a structural recess458, illustrated in FIGS. 13 and 14 as an elongated recess that extendsalong at least a portion of the length of substrate 454.

In one embodiment, coating material 456 may also be applied to at leasta portion of structural recess 458, thereby forming a recess attachmentsurface 464 from the coating material. Recess attachment surface 464 canbe configured to at least partially support a hardware protrusion 462 ofat least one hardware member, shown in FIGS. 13 and 14 as a roller 460,when hardware protrusion 462 is inserted into structural recess 458. Asshown in FIGS. 13 and 14, when inserted into structural recess 458, atleast a portion of hardware protrusion may directly contact at least aportion of recess attachment surface 464. Alternatively, at least aportion of recess attachment surface 464 may be coated with at least oneintervening material layer such that hardware protrusion 462 may be incontact with the intervening layer when inserted into recess 458. Whenpresent, the intervening layer may be coated onto only a portion ofstructural recess 458 and, when recess 458 includes an elongated recess,for example, the partial intervening layer may be disposed at eitherterminal end of recess 458.

As illustrated in FIGS. 13 and 14, structural recess 458 can include abroad section 466 and a narrow section 468 configured to receive a broadportion 470 and a narrow portion 472 of hardware protrusion 462. Wheninserted in structural recess 458, hardware protrusion 462 may bemovable within structural recess 458 in a direction substantiallyparallel to the direction of extension of recess 458. The movement ofhardware protrusion member 462 within structural recess 458 may be atleast partially restrained by the physical dimensions of hardwareprotrusion 472 and/or hardware recess 458. In one embodiment,extrusion-coated structural system 450 may include multiple rollers,each having at least one hardware protrusion configured for simultaneousreceipt into structural recess 458.

Turning now to FIGS. 15 and 16, another extrusion-coated structuralsystem 500 configured according to embodiments of the present inventionis provided. Extrusion-coated structural system 500 comprises anextrusion-coated structural member 512 and at least one hardware member520. Extrusion-coated structural member 512 comprises two substrates 514a, b and a coating material 516 extrusion-coated onto at least a portionof substrates 514 a, b shown in FIGS. 15 and 16. Extrusion-coatedstructural system 500 further comprises a bridging member 515 formed ofcoating material 516 and extending from substrate 514 a to 514 b inorder to coupling substrates 514 a,b to one another. As shown in FIGS.15 and 16, bridging member 515 is configured to permit movement ofsubstrates 514 a and 514 b relative to one another without decouplingsubstrates 514 a and 514 b from each other.

As shown in FIGS. 15 and 16, the extrusion-coated structural member 512comprises a structural recess 518 collectively defined by substrates 514a, b. Structural recess 518 is an elongated recess at least partiallycoated with coating material 516. Structural recess 518 presents arecess attachment surface 524 configured to at least partially supportat least a portion of hardware member 520, shown as a shelf support pinin FIGS. 15 and 16, when hardware member 520 is inserted into structuralrecess 518. The broad portion 526 of hardware member 520 can beconfigured for receipt into the broad section 528 of structural recess518, while the narrow portion 530 of hardware member 520 may beconfigured for receipt into a narrow section 532 of structural recess518.

Once inserted into structural recess 518, hardware member 520 may bemovable within recess 518 in a direction substantially parallel to thedirection of extension of recess 518. In one embodiment, structuralmember 512 can be shiftable between a locked position and an unlockedposition by pivoting at least one of substrates 514 a, b relative to theother via bridging member 515. When structural member 512 is in anunlocked position, as shown in FIG. 15, the movement of hardwareprotrusion 522 within structural recess 518 may be permitted, but whenstructural member 512 is in a locked position, as shown in FIG. 16,movement of hardware protrusion 522 within structural recess 518 issubstantially prevented. When in the locked position, at least onedimension of the structural recess 518 is smaller than when thestructural member 512 is in the unlocked position. Although illustratedin FIGS. 15 and 16 as only including a single hardware member 520, itshould be understood that any suitable number of hardware members couldbe inserted into structural recess 518 and, in one embodiment,structural recess 518 may be configured to receive multiple hardwareprotrusions 522 simultaneously.

Another embodiment of an extrusion-coated structural system 550 isdepicted in FIGS. 17-19. Extrusion-coated structural system 550 includesan extrusion-coated structural member 552 and at least one hardwaremember 560. As shown in FIGS. 17-19, extrusion-coated structural member552 includes a substrate 554 and a coating material 556 extrusion coatedonto at least a portion of substrate 554. Structural member 552 furthercomprises at least one structural recess 558 at least partially coatedwith coating material 556. Structural recess 558 presents a recessattachment surface 564 configured to at least partially support at leasta portion of a hardware protrusion 562 of a hardware member 560. Whenreceived in structural recess 558, hardware protrusion 562 may directlycontact recess attachment surface 564 or at least a portion of hardwareprotrusion 562 may contact at least one layer of intervening material(not shown).

As particularly shown in FIG. 19, structural recess 558 comprises abroad portion 566 and a narrow portion 568 and hardware protrusion 562includes a broad section 570 and a narrow section 572. When inserted instructural recess 558, the narrow section 572 of hardware protrusion 562is configured for receipt in the narrow portion 568 of structural recess558 and broad portion 570 of hardware protrusion 562 can be configuredfor insertion in the broad portion 566 of structural recess 558. Onceinserted, pullout of hardware protrusion 562 from structural recess 558may be inhibited in at least one direction. Additionally, hardwareprotrusion 562 may be configured to move within structural recess 558and, more particularly, may be configured to rotate, thereby changingthe position of hardware member 560, as shown in FIG. 18.

According to another embodiment of the present invention, theextrusion-coated structural member can additionally, or alternatively,include at least one structural protrusion presenting at least oneprotrusion attachment surface formed of the coating material. When thestructural system includes at least one structural member having astructural protrusion, the system may also include at least one hardwaremember comprising at least one hardware recess configured to receive thestructural protrusion therein. Once inserted into the hardware recess,at least a portion of the protrusion attachment surface may be at leastpartially supported by the hardware recess. In one embodiment, theprotrusion attachment surface may maintain direct contact with thehardware recess, while, in another embodiment, the protrusion attachmentsurface and/or the hardware recess may include at least one interveningmaterial layer disposed thereon, such that the protrusion attachmentcontacts the intervening material layer when inserted in the hardwarerecess. Several embodiments of extrusion-coated structural systemsincluding a hardware protrusion are illustrated in FIGS. 20-24.

Turning now to FIGS. 20 and 21, one embodiment of an extrusion-coatedstructural system 600 is illustrated as generally comprising anextrusion-coated structural member 612 and at least one hardware member620. Extrusion-coated structural member 612 includes a substrate 614 anda coating material 616 extrusion coated onto at least a portion ofsubstrate 614. Extrusion-coated structural system 600 illustrated inFIGS. 20 and 21 is similar to the extrusion-coated structural system 550depicted in FIGS. 17-19, except extrusion-coated structural member 612of system 600 comprises a structural protrusion 618 and hardware member620 comprises a hardware recess 622.

As shown in FIGS. 20 and 21, structural protrusion 618 can be at leastpartially coated with coating material 616 and may present a protrusionattachment surface 624 formed of coating material 616. In oneembodiment, at least one intervening layer, shown in FIG. 21 as layer623, may be disposed on at least a portion of structural protrusion 618.Additionally, in one embodiment, at least a portion of hardware member620 may also be coated with a coating material 621, including, forexample, at least a portion of hardware recess 622. When hardware recess622 is at least partially coated with coating material 621, as shown inFIG. 21, hardware recess 622 may present a hardware recess attachmentsurface 625 formed of coating material 621. When structural protrusion618 is inserted in hardware recess 622, at least a portion of theprotrusion attachment surface 624 (or, if present, intervening layer623) of hardware protrusion 618 may be at least partially supported byhardware recess attachment surface 625. In another embodiment, hardwarerecess 624 may also include at least one intervening layer (not shown)disposed on at least a portion of hardware recess attachment surface625.

Structural protrusion 618 also includes a near-protrusion surface 635formed of coating material 616 and located proximate structuralprotrusion 618. In one embodiment, coating material 616 formingprotrusion attachment surface 624 of structural protrusion 618 may becontinuous with the coating material forming near-protrusion surface635. As shown in FIGS. 20 and 21, structural protrusion 618 includes abroad portion 626 and a narrow portion 628, with narrow portion 628 ofstructural protrusion 618 being closer to near-protrusion surface 635than broad portion 626. Broad and narrow portions 626, 628 of structuralprotrusion 618 can be configured for respective insertion into a broadsection 630 and narrow section 632 of hardware recess. In oneembodiment, broad portion 626 of structural protrusion 618 can be widerthan narrow section 632 of hardware recess 622, such that, when insertedinto hardware recess 622, pull out of structural protrusion 618 may beinhibited in at least one direction. Once inserted in hardware recess622, structural protrusion 618 may be configured to move within hardwarerecess 622, thereby permitting movement of hardware member 620 in adirection as generally indicated by arrow 648 in FIG. 20.

In one embodiment, extrusion-coated structural systems 550 and 600 maybe used in cabinetry or furniture applications, such that, for example,extrusion-coated structural member 552 or 612 can be a cabinet box orsupport member of a cabinet or other furniture item, and hardwaremembers 570 or 620 can be a door or other movable component.

Referring now to FIGS. 22 and 23, another embodiment of anextrusion-coated structural system 1650 is illustrated as generallycomprising two extrusion-coated structural members 1652, 1660. In oneembodiment shown in FIGS. 22 and 23, one of extrusion-coated structuralmembers 1652 may comprise a protrusion 1658, while the other 1660 mayinclude a recess 1662 configured to receive protrusion 1658. Althougheach of recess 1662 and protrusion 1658 are defined by respectiveextrusion-coated structural members 1652 and 1662, one ofextrusion-coated structural members 1652 and 1660 may be broadlyconsidered to be a hardware member. Consequently, protrusion 1658 mayeither be a hardware protrusion insertable into structural recess 1662of extrusion-coated structural member 1660 or may be a structuralprotrusion receivable in a hardware recess 1662 of extrusion-coatedstructural member 1660.

As shown in FIGS. 22 and 23, each of extrusion-coated structural members1652, 1662 comprise a substrate 1654, 1670 and a coating material 1656,1672 extrusion-coated onto at least a portion of respective substrates1654, 1670. In one embodiment, at least a portion of protrusion 1658and/or recess 1662 may be coated with respective coating materials 1656,1672, such that protrusion 1658 and/or recess 1672 present respectiveprotrusion and recess attachment surfaces 1664, 1674 formed of coatingmaterial 1656 and 1672. Coating materials 1656 and 1672 may be the sameas or different from each other and, in one embodiment, protrusion 1658and/or recess 1662 may include at least one intervening layer disposedon at least a portion of a recess and protrusion attachment surfaces1664, 1674. When protrusion 1658 is inserted into recess 1662,protrusion attachment surface 1664 can be at least partially supportedby recess attachment surface 1674. Protrusion attachment surface 1664may be directly contacted with recess attachment surface 1674, as shownin FIG. 22, or, if, present, protrusion attachment surface 1664 and/orrecess attachment surface 1674 may contact an intervening layer disposedon at least a portion of the attachment surface of the other.

In one embodiment, extrusion-coated structural system 1650 may be usefulas, for example, a door or window jamb, with extrusion-coated structuralmembers 1652 and 1660 each comprising one portion of the jamb.

Another embodiment of an extrusion-coated structural system 650 isillustrated in FIG. 24 as generally comprising a plurality ofconnectable extrusion-coated structural members 652 a-c, portions ofwhich are shown in FIG. 24. Each extrusion-coated structural member 652a-c includes a respective substrate 654 a-c at least partially coatedwith a coating material 656 a-c. Each of coating materials 656 a-c canbe the same, or at least one of coating materials 656 a-c may bedifferent than one or more of the other coating materials 656 a-c. Asshown in FIG. 24, each of extrusion-coated structural members 652 a-ccomprises a protrusion 658 a-c (658 c not shown in FIG. 24) and a recess660 a-c (660 a not shown in FIG. 24). As described above with theembodiment depicted in FIGS. 22 and 23, each of protrusions 658 a-c maybe considered structural or hardware protrusions and each of recesses660 a-c may be considered structural or hardware recesses.

As shown in FIG. 24, one of more of protrusions 658 a, b and/or recesses660 b, c can be at least partially coated with respective coatingmaterial 656 a-c. One or more of protrusions 658 a,b may present aprotrusion attachment surface 664 a,b at least partially formed ofcoating material 656 a,b-c. Optionally, at least a portion of theprotrusion attachment surface 664 a, b may be defined by or comprise atleast one intervening material layer (not shown in FIG. 24.). In oneembodiment shown in FIG. 24, at least a portion of one or moreprotrusion attachment surfaces 664 a, b may have a thickness that is atleast 1 percent, at least about 2 percent, or at least about 5 percentgreater than the average thickness of the remainder of protrusionattachment surface 664 a, b. In the same or another embodiment, at leasta portion of at least one protrusion attachment surface 664 a, b mayhave a thickness that is at least 1 percent, at least about 2 percent,or at least about 5 percent less than the average thickness of thecoating 656 a, b coated onto the remainder of protrusion attachmentsurface 664 a, and b. Additionally, in one embodiment, at least aportion of protrusion attachment surfaces 664 a,b may have a thicknessat least 1 percent, at least about 2 percent, or at least about 5percent greater than or less than the average thickness of the coatingmaterial 656 a,b forming a near-protrusion surface 668 a,b of structuralmember 652 a,b.

Similarly, in the same or another embodiment, one or more of recesses660 b,-c may present a recess attachment surface 662 b, c formed ofcoating material 656 b, c. In one embodiment shown in FIG. 24, at leasta portion of one or more recess attachment surfaces 662 b, c may have athickness that is at least 1 percent, at least about 2 percent, or atleast about 5 percent greater than the average thickness of theremainder of recess attachment surface 662 b, c. In the same or anotherembodiment, at least a portion of at least one recess attachment surface662 b, c may have a thickness that is at least 1 percent, at least about2 percent, or at least about 5 percent less than the average thicknessof the remainder of recess attachment surface 662 b, c. Additionally, inone embodiment, at least a portion of recess attachment surfaces 662 b,cmay have a thickness at least 1 percent, at least about 2 percent, or atleast about 5 percent greater than or less than the average thickness ofthe coating material 656 b,c forming a near-recess surface 670 b,c (670c not shown) of structural member 652 a-c.

In one embodiment, at least a portion of one or more of protrusionattachment surfaces 664 a, b of protrusions 658 a, b can include atleast one coating cavity (not shown in FIG. 24) and/or at least onecoating projection. In one embodiment, protrusion attachment surfaces664 a, b may include two or more coating cavities (not shown) or two ormore coating projections 680 a, b, as illustrated in FIG. 24. In oneembodiment, one or more of protrusions 658 a, b may include both coatingcavities and protrusions. The ratio of the maximum height of the coatingprojections, or the minimum thickness of the coating cavities, whenpresent, to the average thickness of the coating material 656 a,b coatedonto protrusion 658 a,b can be at least about 0.05:1, at least about0.10:1, at least about 0.25:1, at least about 0.50:1 and/or not morethan about 1:1, not more than about 0.95:1, not more than about 0.75:1,or in the range of from about 0.05:1 to about 1:1, about 0.05:1 to about0.95:1 about 0.05:1 to about 0.75:1, about 0.10:1 to about 1:1, about0.10:1 to about 0.95:1 about 0.10:1 to about 0.75:1, about 0.25:1 toabout 1:1, about 0.25:1 to about 0.95:1 about 0.25:1 to about 0.75:1,about 0.50:1 to about 1:1, about 0.50:1 to about 0.95:1 about 0.50:1 toabout 0.75:1. In another embodiment (not shown in FIG. 24), at least aportion of one or more coating projections and/or one or more coatingrecesses may be defined within a portion of substrate 654.

In the same or another embodiment, at least a portion of one or morerecess attachment surfaces 662 b, c can include at least one coatingcavity and/or at least one coating projection (not shown). In oneembodiment, recess attachment surfaces 662 b, c may include two or morecoating projections (not shown) or two or more coating cavities 682 a,b, as illustrated in FIG. 24. In one embodiment, recess 660 b mayinclude both coating cavities and protrusions. The ratio of the minimumthickness of coating cavities, or the maximum height of the coatingprojections, when present, to the average thickness of the coatingmaterial coated onto recess can be at least about 0.05:1, at least about0.10:1, at least about 0.25:1, at least about 0.50:1 and/or not morethan about 1:1, not more than about 0.95:1, not more than about 0.75:1,or in the range of from about 0.05:1 to about 1:1, about 0.05:1 to about0.95:1 about 0.05:1 to about 0.75:1, about 0.10:1 to about 1:1, about0.10:1 to about 0.95:1 about 0.10:1 to about 0.75:1, about 0.25:1 toabout 1:1, about 0.25:1 to about 0.95:1 about 0.25:1 to about 0.75:1,about 0.50:1 to about 1:1, about 0.50:1 to about 0.95:1 about 0.50:1 toabout 0.75:1. In another embodiment (not shown in FIG. 24), at least aportion of one or more coating projections and/or one or more coatingrecesses may be defined within a portion of substrate 654 b, c.

In the embodiment depicted in FIG. 24, protrusion attachment surface 664a of extrusion-coated structural member 652 a is illustrated ascomprising a pair of coating projections 680 a, b disposed on generallyopposing sides of protrusion 658 a. As shown in FIG. 24, protrusion 658a of extrusion-coated structural member 652 a is configured forinsertion into a recess 660 b of extrusion-coated structural member 652b. Recess attachment surface 662 b of recess 660 b can include at leastone coating cavity, shown in FIG. 24 as a pair of coating cavities 682a, b, disposed on generally opposing sides of recess 660. Upon insertionof protrusion 658 a into recess 660 a, coating projections 680 a, b mayalso be inserted into corresponding coating cavities 682 a, b therebyfurther securing and supporting protrusion 658 a within recess 660 a.When extrusion-coated structural system 650 includes two or moreextrusion-coated structural members 652 a-c, as shown in FIG. 24, eachstructural member 652 a-c may include similar features such that eachstructural member 652 a-c may be coupled to one or more other structuralmembers 652 a-c as generally shown in FIG. 24. The extrusion-coatedstructural system 650 depicted in FIG. 24 may be particularly useful inconstruction applications as, for example, wall or floor panels.

According to another embodiment of the present invention, one or morerecesses or protrusions defined by an extrusion-coated structural membercan be at least partially formed by an extruded profile member formed ofthe coating material. As used herein, the term “extruded profile member”refers to a portion of an extrusion-coated structural member that isseparate, but extends outwardly from, at least a portion of one or moresubstrates included in the structural member. In one embodiment, theextruded profile member may extend outwardly from the substrate of theextrusion-coated structural member and may also extend along at least aportion of the length of the substrate.

In one embodiment, the extruded profile member may extend outwardly fromthe substrate for a maximum distance that is at least about two, atleast about five, at least about ten, at least about 20 times greaterthan the average thickness of the coating material extruded onto thesubstrate at a location adjacent the extruded profile member. Theaverage thickness of the coating material extrusion coated onto thesubstrate at a location adjacent the extruded profile member can bewithin the ranges described previously. The ratio of the maximumthickness of the extruded profile member to the average thickness of thecoating material extrusion coated onto the substrate at a locationadjacent the extruded profile member can be at least about 1:1, at leastabout 2:1, at least about 3:1 and/or not more than about 10:1, not morethan about 8:1, not more than about 6:1, or in the range of from about1;1 to about 10:1, about 1:1 to about 8:1, about 1:1 to about 6:1, about2:1 to about 10:1, about 2:1 to about 8:1, about 2:1 to about 6:1, about3:1 to about 10:1, about 3:1 to about 8:1, about 3:1 to about 6:1.

In the same or another embodiment, the extruded profile member mayextend along at least about 50 percent, at least about 60 percent, atleast about 70 percent, at least about 80 percent, or at least about 90percent of the total length of the substrate, such that the ratio of thelength of the extruded profile member to the ratio of the length of thesubstrate is at least about 0.50:1, at least about 0.60:1, at leastabout 0.70:1, at least about 0.80:1, or at least about 0.90:1. Theextruded profile member can extend continuously along the length of thesubstrate.

The extruded profile member can be at least partially, or nearlyentirely, formed of the coating material applied onto the substrateduring formation of the extrusion-coated structural member and may, forexample, be formed simultaneously during the extrusion coating processused to produce the extrusion-coated structural member, additionaldetails of which will be discussed in detail shortly. In one embodiment,not more than about 20, not more than about 10, not more than about 5,not more than about 2 percent of the total volume of the extrudedprofile member may be occupied by the substrate and, in the same oranother embodiment, at least about 5 percent, at least about 10 percent,at least about 15 percent, at least about 20 percent, or at least about25 percent of the total weight of coating material applied to thesubstrate to form the extrusion-coated structural member may be used toform the extruded profile member.

In one embodiment, the extruded profile member of an extrusion-coatedstructural member may at least partially define at least one profilerecess and/or at least one profile protrusion. When present, the profilerecess may at least partially define a profile recess attachment surfaceconfigured to contact and at least partially support a hardware,structural, or profile protrusion inserted therein. Similarly, whenpresent in the extrusion-coated structural member, the profileprotrusion at least partially defined by the extruded profile member maypresent a protrusion profile attachment surface configured to contact atleast a portion of a structural recess, a hardware recess, and/or aprofile recess when inserted therein. In one embodiment, the extrudedprofile member can define at least about 50, at least about 60, at leastabout 70, at least about 80, or at least about 90 percent of the totalarea of recess attachment and/or profile attachment surfaces, and, inone embodiment, the entirety of the recess and/or profile attachmentsurfaces may be defined by the extruded profile member.

According to one embodiment, at least a portion of the profile recessattachment surface and/or the profile protrusion attachment surface cancomprise one or more coating cavities and/or coating projections. Whenpresent, the coating cavities and/or projections may extend along atleast a portion of the profile protrusion and/or profile recessattachment surfaces and can define areas of coating have a thicknessthat is at least about 1, at least about 2, at least about 3, at leastabout 5 percent greater than the average thickness of the profileprotrusion and/or profile recess attachment surfaces.

In one embodiment, the profile protrusion attachment surface of anextruded profile member can include two or more coating cavities and/ortwo or more coating projections. In one embodiment, the profileprotrusion attachment surface may include both coating cavities andprotrusions. The ratio of the maximum height of the coating projectionsor the minimum thickness of the coating cavities, when present, to theaverage thickness of the coating material forming the profile protrusionattachment surface can be at least about 0.05:1, at least about 0.10:1,at least about 0.25:1, at least about 0.50:1 and/or not more than about1:1, not more than about 0.95:1, not more than about 0.70:1, or in therange of from about 0.05:1 to about 1:1, about 0.05:1 to about 0.95:1,about 0.05:1 to about 0.70:1, about 0.10:1 to about 1:1, about 0.10:1 toabout 0.95:1, about 0.10:1 to about 0.70:1, about 0.25:1 to about 1:1,about 0.25:1 to about 0.95:1, about 0.25:1 to about 0.70:1, about 0.50:1to about 1:1, about 0.50:1 to about 0.95:1, about 0.50:1 to about0.70:1.

In the same or another embodiment, at least a portion of one or moreprofile recess attachment surfaces can include at least one coatingcavity and/or at least one coating projection. In one embodiment, theprofile recess attachment surface may include both coating cavities andprotrusions. The ratio of the maximum height of the coating projectionsor the minimum thickness of the coating cavities, when present, to theaverage thickness of the coating material forming the profile recessattachment surface can be at least about 0.05:1, at least about 0.10:1,at least about 0.25:1, at least about 0.50:1 and/or not more than about1:1, not more than about 0.95:1, not more than about 0.70:1, or in therange of from about 0.05:1 to about 1:1, about 0.05:1 to about 0.95:1,about 0.05:1 to about 0.70:1, about 0.10:1 to about 1:1, about 0.10:1 toabout 0.95:1, about 0.10:1 to about 0.70:1, about 0.25:1 to about 1:1,about 0.25:1 to about 0.95:1, about 0.25:1 to about 0.70:1, about 0.50:1to about 1:1, about 0.50:1 to about 0.95:1, about 0.50:1 to about0.70:1.

Several embodiments of extrusion-coated structural systems that includetwo or more extrusion-coated structural members having at least oneextruded profile member are provided in FIGS. 25-30. Turning initiallyto FIGS. 25 and 26, an extrusion-coated structural system 700 isillustrated as generally comprising a pair of extrusion-coatedstructural members 712, 722. Each of structural members 712, 722includes a substrate 714, 724 and a coating material 716, 726 extrusioncoated onto at least a portion of substrate 714, 724. Coating materials716 and 726 may be the same or different. As shown in FIGS. 25 and 26,extrusion-coated structural member 722 comprises a structural protrusion728 at least partially coated with a coating material 726 andextrusion-coated structural member 712 includes a profile recess 718 atleast partially defined by extruded profile member 730. In oneembodiment shown in FIGS. 25 and 26, profile recess 718 can be entirelyformed by extruded profile member 730 and may not be defined bysubstrate 714.

Profile recess 718 can present a profile recess attachment surface 740that is at least partially formed from coating material 726 used to formextruded profile member 730. In the embodiment shown in FIGS. 25 and 26,at least a portion of profile recess attachment surface 740 comprises aplurality of coating cavities 742. Alternatively, profile recessattachment surface could additionally include at least one coatingprojection or could alternatively include only coating projections (notshown in FIGS. 25 and 26). Further, as shown in FIGS. 25 and 26, theprofile protrusion attachment surface 738 presented by structuralprotrusion 728 can also include one or more coating projections 744and/or one or more coating cavities (not shown) spaced along profileprotrusion attachment surface 738.

The coating cavities 742 and projections 744 respectively defined byprofile recess and profile protrusion attachment surfaces 740 and 738may have the maximum height and/or minimum depth, relative to theaverage thickness of the coating material forming profile recess and/orprofile protrusion attachment surfaces as described in detailpreviously. Further, although shown in FIGS. 25 and 26 as comprisinggenerally semi-circular cavities, coating cavities 742 and/or coatingprojections 744 could have any desirable shape. Further, as illustratedin FIGS. 25 and 26, each of coating cavities 742 and coating projections744 can extend along at least a portion of the length of substrates 714,724 and/or along at least a portion of the respective lengths ofextruded profile member 730 and structural protrusion 728.

To assemble extrusion-coated structural system 700, profile protrusion728 may be inserted into profile recess 718 such that at least a portionof profile recess attachment surface is in direct contact with at leasta portion of profile protrusion 728. When inserted into profile recess718, at least a portion, or all, of the coating projections 744 disposedon profile protrusion attachment surface 783 of protrusion 728 can beinserted into a corresponding coating cavity 742 defined by profilerecess attachment surface 740 of recess 718. In one embodiment, one ofcoating projections 744 of profile protrusion 728 may be insertable intomore than one coating cavities 742 of profile recess 718 such that theposition of extrusion-coated structural members 712 and 722 may beadjustable relative to one another.

Turning now to FIGS. 27 and 28, one embodiment of an extrusion-coatedstructural system 750 is illustrated as generally comprising a pair ofextrusion-coated structural members 752, 762. Each of extrusion-coatedstructural members 752, 762 includes a substrate 754, 764 and a coatingmaterial 756, 766 extrusion coated onto at least a portion of substrates754, 764. Extrusion-coated structural system 750 is similar toextrusion-coated structural system 700 described previously with respectto FIGS. 25 and 26, except each of extrusion-coated structural members752, 762 of structural system 750 includes an extruded profile member770, 780. Further, as shown in FIGS. 27 and 28, each of extruded profilemembers 770, 780 include a pair of profile projections 772 a, b and 782a, b and a profile recess 774, 784 disposed therebetween.

As shown in particular by FIG. 28, extrusion-coated structural members752 and 762 can be coupled to one another by inserting profileprojection 772 b of extruded profile member 770 into profile recess 784of extruded profile member 780 and, at the same time, inserting profileprojection 782 b of extruded profile member 780 into profile recess 774of extruded profile member 770. In this way, at least a portion of theattachment surface 786 presented by extruded profile member 780 can bein contact with at least a portion of the attachment surface 776presented by extruded profile member 770. Although shown in FIGS. 27 and28 as having a generally beveled shape, extruded profile member 770 and780 may have any other suitable shapes.

Turning now to FIGS. 29 and 30, another embodiment of anextrusion-coated structural system 800 similar to the extrusion-coatedstructural system 700 and 750 described previously, is provided.Extrusion-coated structural system 800 includes a plurality ofextrusion-coated structural members 812 that each includes a substrate814 and a coating material 816 extrusion coated onto at least a portionof substrate 814. Coating materials 816 coated onto each substrate 816can be the same as, or different than, the coating material 816 coatedonto one or more other substrates 814. As shown in FIGS. 29 and 30, eachof structural members 812 comprises an extruded profile member 820 and arecess 822 configured to receive the profile member 820 of anothersubstrate 814. In one embodiment, substrate 814 includes a coatingmaterial 816 which can at least partially define recess 822, while, inanother embodiment (not shown), recess 822 can be entirely formed ofcoating material 816.

To assemble extrusion-coated structural system 800, the extruded profilemember 820 of one extrusion-coated structural member may be insertedinto the recess 822 of a second extrusion-coated structural member tothereby couple structural members 812 a and b to each other. Optionally,extruded profile member 820 may be further secured in recess 822 throughuse of adhesive (not shown) or by treating the points of connectionamongst the assembled structural members 812 using, for example, heat orultrasonic energy. Once secured, one or more of the structural members812 may be moved relative to one or more other structural member inorder to form the assembled structural member into a variety of shapes,preferably without uncoupling the individual structural members 812 fromone another. Although shown as including only 4 extrusion-coatedstructural members 812, structural system 800 may include any suitablenumber of structural members, such as, for example, at least 2, at least4, at least 6 and/or not more than 20, not more than 15, not more than10. Extrusion-coated structural system 800 may be useful in a widevariety of applications but, in particular, may be utilized in aconstruction application as, for example, floor or wall paneling.

Turning now to FIGS. 31 and 32, another embodiment of anextrusion-coated structural member 852 including an extruded profilemember 870 is provided. Extrusion-coated structural member 852 includesa substrate 854 and a coating material 856 extrusion coated onto atleast a portion of substrate 854. In one embodiment, theextrusion-coated structural member 852 includes at least one extrudedprofile member 870 that extends outwardly from substrate 854 for amaximum distance, indicated by the letter L in FIG. 32, of at leastabout 0.25 inches, at least about 0.5 inches, at least about 0.75 inchesand/or not more than 4 inches, not more than about 3 inches, not morethan about 2 inches. the extrusion-coated structural member 852 includesat least one extruded profile member 870 that extends outwardly fromsubstrate 854 for a maximum distance in the range of from about 0.25 toabout 4 inches, about 0.25 to about 3 inches, about 0.25 to about 2inches, about 0.5 to about 4 inches, about 0.5 to about 3 inches, about0.5 to about 2 inches, about 0.75 to about 4 inches, about 0.75 to about3 inches, about 0.75 to about 2 inches.

According to one embodiment, the ratio of the maximum distance, L, ofextension of extruded profile member 870 from substrate 854 to themaximum thickness of the extruded profile member may be at least about0.5:1, at least about 1:1, at least about 2:1, at least about 5:1 and/ornot more than about 20:1, not more than about 15:1, not more than about10:1, not more than about 8:1, not more than about 6:1. The ratio can bein the range of from about 0.5:1 to about 20:1, about 0.5:1 to about15:1, about 0.5:1 to about 10:1, about 0.5:1 to about 8:1, about 0.5:1to about 6:1, about 1:1 to about 20:1, about 1:1 to about 15:1, about1:1 to about 10:1, about 1:1 to about 8:1, about 1:1 to about 6:1, about2:1 to about 20:1, about 2:1 to about 15:1, about 2:1 to about 10:1,about 2:1 to about 8:1, about 2:1 to about 6:1, about 5:1 to about 20:1,about 5:1 to about 15:1, about 5:1 to about 10:1, about 5:1 to about8:1, about 5:1 to about 6:1. In the embodiment depicted in FIGS. 31 and32, structural member 852 can comprise a profile cavity 818 that is atleast partially, or nearly entirely, defined by extruded profile member870. Extruded profile member 870 depicted in FIGS. 31 and 32 comprises ashock absorbing member shiftable between an extended position, asindicated by the solid lines in FIG. 32, and a compacted position, asindicated by the dashed lines in FIG. 32. Upon contact with a surface ofa second structural member (not shown), shock absorbing member 870 canshift from an extended position to a compacted position, therebyabsorbing or lessening at least a portion of the contact energytransferred between the structural members. Extrusion-coated structuralmember 852 may be useful as a door or drawer in a variety of furnitureor cabinetry applications.

Additional embodiments of extrusion-coated structural systems includingextruded profile member are provided in FIGS. 33-36. Each ofextrusion-coated structural system 900 and extrusion-coated structuralmember 952 respectively depicted in FIGS. 33 and 34 and FIGS. 35 and 36include at least one extrusion-coated structural member and one or moreextruded profile member used to enhance the aesthetic appeal and/orfunctionality of the structural system. For example, in the embodimentsdepicted in FIGS. 33 and 34, extrusion-coated structural system 900comprises two extrusion-coated structural members 912, 922 eachincluding a substrate 914, 924 and a coating material 916, 926 extrusioncoated to at least a portion of substrate 914, 924.

As shown in FIGS. 33 and 34, one of extrusion-coated structural member912 includes a first elongated structural recess 918 and at least twoother structural recesses 917 a, b configured to receive a portion oftwo hardware members, shown in FIGS. 33 and 35 as comprising screws 930a, b. The other extrusion-coated structural member 920 includes anextruded profile member, shown as a tab 940, extending outwardly fromone of the surfaces 915 a of substrate 924, continuous with coatingmaterial 926 applied to surface 915 a. Tab 940 includes a pair ofprojections 942 a, b configured to be received within structural recess918 of extrusion-coated structural member 912. When inserted intostructural recess 918, as shown in FIG. 34, tab 940 may be suitable forhiding one or more hardware members, such as screw 930 a from view whenthe structural members 912, 922 are assembled to form structural system900. Thus, extruded profile member 940 may be used to increase theaesthetic properties of a structural system.

Turning now to FIGS. 35 and 36 another embodiment of an extrusion-coatedstructural member 952 exhibiting enhanced functional and/or aestheticcharacteristics are provided. As shown in FIGS. 35 and 36,extrusion-coated structural member 952 comprises a substrate 954 and acoating material 956 extrusion coated onto at least a portion ofsubstrate 954. As shown in the embodiment depicted in FIGS. 35 and 36,structural member 952 includes an extruded profile member 970 extendingoutwardly from at least a portion of substrate 954 and being continuouswith coating material 956 coated onto the portion of substrate 954adjacent extruded profile member 970. Rather than include an unsupportedterminal end, like another embodiment of extruded profile memberpreviously discussed, extruded profile member 970 illustrated in FIGS.35 and 36 extends between and is supported by each of a first and secondportion 953 a,b of substrate 954. As a result, extruded profile member970 forms a portion of profile recess 958, although less than 50 percentof the total area of the inner surface area of profile recess 958 isdefined by extruded profile member 970.

In one embodiment shown in FIGS. 35 and 36, profile recess 958 can beconfigured to receive at least one functional and/or aesthetic member toenhance the functionality and/or aesthetic characteristics of thestructural member and/or structural system. Examples of suitablefunctional and/or aesthetic members suitable for insertion into aprofile recess, such as profile recess 958, can include, but are notlimited to, piping, electrical conduit or wires, cables, lightingelements or fixtures, LED elements, and combinations thereof. In theembodiment shown in FIGS. 35 and 36, a plurality LED elements 980 can beinserted into profile recess 958 to enhance the functionality and/oraesthetics of structural member 952.

According to one or more other embodiments of the present invention, oneor more structural systems as described herein may include at least onebridging member coupling two or more substrates to one another in orderto permit movement of at least one substrate relative to the other. Inone embodiment, the structural system of the present invention cancomprise at least two substrates and at least one bridging membercoupling the first and second substrates to one another. The bridgingmember can be formed of a coating material extrusion coated onto atleast a portion of the first and second substrates and may extend fromat least a portion of the one of the substrates to at least a portion ofone of the other substrates to thereby form an extrusion-coatedstructural member.

According to one embodiment, the bridging member may be the onlyconnection between the substrates being coupled. In one embodiment, themaximum thickness of the bridging member can be greater than the averagethickness of the coating material applied to the substrate adjacent thebridging member, while, in another embodiment, the maximum thickness ofthe bridging member can be approximately the same as the averagethickness of the coating material applied to the substrate adjacent thebridging member. The ratio of the maximum thickness of the bridgingmember to the average thickness of the coating material applied to thesubstrate proximate the bridging member can be at least about 0.9:1, atleast about 1:1, at least about 1.5:1, at least about 2:1 and/or notmore than about 10:1, not more than about 8:1, not more than about 6:1.The ratio of the maximum thickness of the bridging member to the averagethickness of the coating material applied to the substrate proximate thebridging member can be in the range of from about 0.9:1 to about 10:1,about 0.9:1 to about 8:1, about 0.9:1 to about 6:1, about 1:1 to about10:1, about 1:1 to about 8:1, about 1:1 to about 6:1, about 1.5:1 toabout 10:1, about 1.5:1 to about 8:1, about 1.5:1 to about 6:1, about2:1 to about 10:1, about 2:1 to about 8:1, about 2:1 to about 6:1.

In another embodiment, the ratio of the bridging member to thethickness, or shortest dimension, of the substrate can be at least about0.005:1, at least about 0.01:1, at least about 0.05:1 and/or not morethan 0.50:1, not more than about 0.25:1, not more than about 0.10:1, orin the range of from about 0.005:1 to about 0.50:1, about 0.005:1 toabout 0.25:1, about 0.005:1 to about 0.10:1, about 0.01:1 to about0.50:1, about 0.01:1 to about 0.25:1, about 0.01:1 to about 0.10:1,about 0.05:1 to about 0.50:1, about 0.05:1 to about 0.25:1, about 0.05:1to about 0.10:1.

The maximum thickness of the bridging member can be at least about 0.005inches, at least about 0.010 inches, at least about 0.050 inches, atleast about 0.075 inches and/or not more than about 0.75 inches, notmore than about 0.50 inches, not more than about 0.25 inches, or notmore than about 0.15 inches. The bridging member can have asubstantially constant thickness, or at least one portion of thebridging member can have a thickness different than at least one otherportion of the bridging member. The ratio of the maximum thickness ofthe bridging member to the maximum thickness of the substrates beingcoupled can be at least about 0.001:1, at least about 0.005:1, at leastabout 0.010:1, at least about 0.050:1 and/or not more than about 0.5:1,not more than about 0.25:1, not more than about 0.20:1.

The substrates coupled by the at least one bridging member can have anysuitable shape and/or size and can be arranged in any suitableconfiguration. In one embodiment, the length, width, and depth of eachof the substrates being coupled may be the same or substantially thesame, while, in another embodiment, at least one of the substrates beingcoupled may have a length, width, and/or depth different than thelength, width, and/or depth of at least one other substrates beingcoupled. As used herein, the term “substantially” means within 5percent. According to one embodiment, three or more substrates may becoupled with at least one bridging member and at least one of thesubstrates may have a different size, shape, and/or orientation than atleast one of the others. In one embodiment, all of the substratescoupled with the bridging member may have the same size, shape, and/ororientation of each of the other substrates.

The position of the substrates within the extrusion-coated structuralsystem may vary, depending on the specific design and use of the system.In one embodiment, the substrates of the structural system may bepositioned in a side-by-side arrangement such that lengths andthicknesses of adjacent substrates are substantially parallel to oneanother and the widths are substantially aligned. As used herein, theterm “substantially” means within 5° and “aligned” means extending alongthe same axis. In another embodiment, the substrates of the structuralsystem may be configured in a “top-to-bottom” arrangement such thatlengths and widths of adjacent substrates are substantially parallel toone another and the thicknesses are substantially aligned. Further, inyet another embodiment, the substrates may be arranged in an“end-to-end” arrangement such that widths and thicknesses of adjacentsubstrates are substantially parallel to one another and the lengths aresubstantially aligned. In a still further embodiment, the substrates maybe arranged in a “nested” arrangement, wherein one or more substratesare positioned within a recess or cavity defined by one or more othersubstrates. Various embodiments having substrates arranged in each ofthese configurations will be discussed in detail shortly.

In one embodiment, the structural systems that include at least onebridging member may be shiftable between a flat configuration, whereinthe bridging member extends between the first and second substrates in asubstantially planar fashion, and a folded configuration, wherein atleast a portion of the bridging member is bent, flexed, folded, orotherwise arranged in a non-planar way. According to one embodiment, thebridging member may be configured to permit movement of the substratesfrom a flat configuration to a folded configuration (and back to a flatconfiguration) without decoupling the substrates from one another.During the shifting, one of the substrates can be moved relative to theother by, for example, bending, rotating, or flexing at least a portionof the bridging member. In one embodiment, the bridging member may beconfigured to permit a maximum angular range of motion of at least about15°, at least about 30°, at least about 45°, at least about 60°, atleast about 75°, at least about 90°, at least about 135° and/or not morethan about 180°, not more than about 135°, not more than about 90°, notmore than about 75° of one substrate relative to the other.

When in the flat configuration, the substrates of the structural systemmay be spaced apart from one another to define a gap, and at least aportion of the bridging member may extend across the gap from at least aportion of one substrate to at least a portion of the other. The gap maybe at least partially defined by opposing surfaces of each of thesubstrates which can be, in some cases, aligned substantially parallelto each other, when the structural system is in the flat configuration.In another embodiment, the opposing surfaces of adjacent substrates maybe oriented at an alignment angle of at least about 5°, at least about15°, at least about 30°, at least about 45°, at least about 60° and/ornot more than about 160°, not more than about 135°, not more than about110°, or not more than about 90° with respect to one another.

When present, one or more dimensions of the gap defined between thesubstrates may change as the structural system is shifted from a flatconfiguration to a folded configuration and, in some cases, the gap maynot be present when the structural system is in a folded configuration.When configured in the flat configuration, the width of the gap, ifpresent, may be constant along the length and/or depth of the gap.Alternatively, the width the gap may change (i.e., increase and/ordecrease) along the length and/or depth thereof. As used herein, the“length” of the gap is measured in a direction parallel to the directionof extension of the substrates, and the “width” of the gap is measuredin a direction parallel to the direction of extension of the bridgingmember. As used herein the “depth” of the gap is measured in a directionperpendicular to both the width and the length of the gap and, in oneembodiment, can be parallel to the thickness of the substrates beingcoupled. In one embodiment, the ratio of the minimum width of the gap tothe maximum width of the gap may be at least about 0.25:1, at leastabout 0.50:1, at least about 0.75:1 and/or not more than about 1:1, notmore than about 0.90:1, not more than about 0.85:1 and/or the ratio ofthe depth of the gap to the maximum width of the gap can be at leastabout 0.10:1, at least about 0.25:1, at least about 0.40:1 and/or notmore than about 3:1, not more than about 2:1, not more than about 1:1,not more than about 0.85:1.

Several embodiments of extrusion-coated structural systems including astructural member having at least one bridging member are provided inFIGS. 37-58. Turning first to FIGS. 37 and 38, one embodiment of anextrusion-coated structural member 1010 is illustrated as generallycomprising a pair of substrates 1012, 1014 and at least two bridgingmembers 1040, 1042 extending from at least a portion of substrate 1012to at least a portion of substrate 1014. In one embodiment, substrates1012 and 1014 are formed of the same substrate material, while, inanother embodiment, substrates 1012 and 1014 may be formed of differentmaterials. Similarly, bridging members 1040 and 1042 can be formed ofdifferent coating materials, but, in a preferred embodiment, bothbridging members 1040 and 1042 can be formed of a single materialextrusion coated onto at least a portion of extrusion-coated structuralmember 1010.

In one embodiment depicted in FIGS. 37 and 38, at least a portion ofsubstrates 1012, 1014 can be in direct contact such that one or more ofthe outer surfaces 1022 a (1022 b not shown) of one substrate 1012 andone or more of the outer surface 1024 a (1024 b not shown) of the othersubstrate 1014 collectively form at least one composite surface 1040 a,b as shown in FIG. 38. In one embodiment, bridging members 1040 and 1042may extend along respective composite surfaces 1040 a,b from at least aportion of outer surfaces 1022 a,b of substrate 1012 to at least aportion of outer surfaces 1024 a,b of substrate 1014 thereby formingextrusion-coated structural member 1010. In one embodiment shown inFIGS. 37 and 38, the extrusion-coated structural member may define aninterior structural recess 1018, which can optionally be configured toreceive one or more functional or aesthetic elements (not shown), suchas, for example, one or more elements listed above.

Turning now to FIGS. 39-41, another embodiment of an extrusion-coatedstructural system 1050 is illustrated as comprising a pair of substrates1052, 1054 and a bridging member 1060 coupling substrates 1052 and 1054to one another. Bridging member 1060 can be formed of a coating material1056 and may extend from at least a portion of substrate 1052 to atleast a portion of substrate 1054. When substrates 1052 and 1054 arealso coated with a coating material 1056, as shown in the embodiment inFIGS. 39-41, at least a portion of the coating material 1056 disposed onsubstrates 1052 and 1054 can be continuous with bridging member 1060.

When structural system 1050 is configured in a flat configuration, asgenerally shown in FIG. 39, substrates 1052 and 1054 can be spaced apartfrom one another to form a gap 1070. As shown in FIG. 39, gap 1070 is atleast partially defined by opposing surfaces 1064, 1066 of respectivesubstrates 1052, 1054, which are arranged substantially parallel to oneanother and at least partially coated with coating material 1056 and maybe continuous with the material used to coat substrates 1052, 1054and/or may be continuous with the coating material 1056 used to formbridging member 1070.

As structural system 1050 is shifted from a flat configuration to one orboth of the folded configurations shown in FIGS. 40 and 41, the sizeand/or shape of gap 1070 may change. For example, when shiftingstructural system 1050 from a flat configuration to a foldedconfiguration, the size of gap 1070 may increase, while, when shiftingstructural system 1050 from a folded configuration to a flatconfiguration, the size of gap 1070 may decrease. Structural systemsconfigured similarly to structural system 1050 may have a variety of enduses and, in one embodiment, may be suitable for use as a trim piece orother component in a variety of indoor and/or outdoor constructionapplications.

Referring now to FIGS. 42-44, yet another embodiment of anextrusion-coated structural system 1100 configured according to thepresent invention is provided. Extrusion-coated structural system 1100comprises a pair of substrates 1112, 1114 and a bridging member 1120extending between at least a portion of substrates 1112 and 1114.Extrusion-coated structural system 1100 is similar to theextrusion-coated structural system 1050 depicted in FIGS. 39-41, with atleast the following differences.

When structural system 1100 is arranged in a flat configuration, asshown in FIG. 42, substrates 1112 and 1114 can define a gap 1130 therebetween. In contrast to gap 1070 depicted in FIGS. 39-41, opposingsurfaces 1132, 1134 of substrates 1112, 1114 shown in FIGS. 42-44 arenot parallel, but instead are angularly aligned with one another at analignment angle, shown as e in FIG. 42, measured from surface 1132 ofsubstrate 1112 to surface 1134 of substrate 1114. In one embodiment, thealignment angle can beat least about 5°, at least about 15°, at leastabout 30°, at least about 45°, at least about 60° and/or not more thanabout 160°, not more than about 135°, not more than about 110°, or notmore than about 90°. Additionally, as particularly shown in FIG. 42, thewidth of gap 1130 changes along its depth. For example, as shown in FIG.42, the width of the gap narrows nearer bridging member 1120, such thatgap 1130 has a general “V”-shaped cross-section.

When structural system 1100 is shifted between a flat configuration, asshown in FIG. 42, to a folded configuration, as shown in FIG. 43, gap1130 is no longer present and opposing surfaces 1132 and 1134 maycontact one another. Additionally, when in the folded configurationshown in FIG. 43, substrates 1112 and 1114 may collectively define astructural recess 1118 configured to receive a hardware member, shown asstructural member 1120 in FIG. 44, to thereby secure structural system1100 in a folded configuration. Alternatively, other recessconfigurations and other types of hardware may be used or, in oneembodiment, an adhesive material such as, for example, double-sided tapeor glue, may also be used to secure structural system 1100 in a foldedconfiguration. Hardware member 1120 may be used to secure structuralsystem 1100 in a folded configuration permanently or may be removablesuch that structural system 1100 can be shifted back to a flatconfiguration, as shown in FIG. 42.

Turning now to FIGS. 45 and 46, another embodiment of anextrusion-coated structural system 1150 is illustrated as generallycomprising a plurality of substrates 1152 a-f and a coating material1156 extrusion coated onto at least a portion of substrates 1152 a-f. Inone embodiment, substrates 1152 a-f may be coupled to one another by atleast one bridging member 1170 extending from one or more of thesubstrates 1152 a-e to one or more other substrates 1152 a-e. Accordingto the embodiment shown in FIGS. 45 and 46, bridging member 1170 may bea single bridging member 1170 extending continuously from a firstsubstrate, shown as substrate 1152 a, along the length of structuralsystem 1150 to a last substrate, shown as 1152 e. Alternatively, each ofbridging members 1170 a-d may have been separately formed and may, inone embodiment, be formed of a coating material different than coatingmaterial 1156 and/or may discontinuous with at least a portion ofcoating material 1156.

Structural system 1150, as shown in FIGS. 45 and 46, may be formed inany suitable manner. In one embodiment, several individual, butsimilarly shaped, substrates 1152 a-e may be simultaneously extrusioncoated while maintaining a space between the substrates to thereby forma bridging member 1170 that spans at least a portion of the spacebetween substrates 1152 a-e. In another embodiment, a single elongatedsubstrate may be at least partially coated with coating material 1156and a plurality of gaps 1174 a-e may then be cut into the coatedsubstrate at various locations along its length to thereby formsubstrates 1152 a-e, as shown in FIG. 46. When cutting gaps 1174 a-e,coating material 1156 extending along at least one of the surfaces ofsubstrate 1152 may remain intact, thereby forming bridging member 1170,as shown in FIGS. 45 and 46.

Structural system 1150 can be shiftable between a flat configuration, asillustrated in FIG. 45, and a folded configuration, as illustrated inFIG. 46. In one embodiment, when in a folded configuration, at least onesurface 1162 a of a substrate 1152 a may be contacted with at least onesurface 1162 f of another substrate 1152 f to thereby form a closedconfiguration as generally shown in FIG. 46. When in said closedconfiguration, structural system 1150 may have a circular or polygonalshape, depending, in part, on the size, shape, and number of individualsubstrates. In the embodiment shown in FIG. 46, structural system 1150may be configured so that bridging member 1170 forms a continuousexternal surface 1173 amongst substrates 1152 a-f. In one embodiment, asecuring device, including, for example, a hardware member or adhesivematerial (not shown) may be used, if desired, to secure surfaces 1162 aand 1162 f to each other.

Referring now to FIGS. 47-49, another extrusion-coated structural system1200 is illustrated as comprising a plurality of substrates 1212 a-h anda coating material 1216 extrusion coated onto at least a portion ofsubstrates 1212 a-h. Substrates 1212 a-h may be coupled to one anotherby at least one bridging member 1240 extending along at least a portionof one or more of the substrates 1212 a-h. Extrusion-coated structuralsystem 1200 is similar to the extrusion-coated structural system 1150described previously with respect to FIGS. 45 and 46, with at least thefollowing differences.

As shown in FIGS. 47-49, structural system 1200 includes a plurality ofsubstrates 1212 a-h spaced apart from one another to form a plurality ofgaps 1230 a-g. Each of gaps 1230 a-g is at least partially defined byopposing surfaces of adjacent substrates 1212 a-h which are alignedsubstantially parallel to one another. Further, as shown in FIG. 48, thewidth of each of gaps 1230 a-g can be substantially constant over thedepth of the gaps 1230 a-g and, as shown in one embodiment depicted inFIG. 47, the direction of extension one or more gaps 1230 a-g may or maynot be substantially parallel with the direction of extension of one ormore other gaps 1230 a-g and/or with one or more edges 1213 a, b ofstructural system 1200. As a result, when structural system 1200 isshifted into a folded configuration, as shown in FIG. 49, bridgingmember 1240 may form a continuous surface 1236 located inside the closedportion of structural system 1200. Additionally, rather than contractwhen the structural system is shifted into a folded configuration atleast a portion of gaps 1230 a-g of structural system 1200 expand whenstructural system 1200 is shifted from a flat configuration to a foldedconfiguration, as particularly shown in FIGS. 48 and 49.

Referring now to FIGS. 50 and 51, yet another embodiment of anextrusion-coated structural system 1250 is illustrated as comprising aplurality of substrates 1252 a-h and a coating material 1256 extrusioncoated onto at least a portion of substrates 1252 a-h. As shown in FIGS.50 and 51, at least a portion of coating material 1256 may be formedinto a bridging member 1240 extending from at least a portion of one ormore substrates 1252 a-h to at least a portion of one or more othersubstrates 1252 a-h. In one embodiment shown in FIGS. 50 and 51,bridging member 1240 may extend continuously between each of substrates1252 a-h, while, in another embodiment (not shown), at least a portionof bridging member 1240 may not be continuous along the length ofsubstrates 1252 a-h. As shown in FIGS. 50 and 51, at least a portion ofsubstrates 1252 a-h may not contact one another, but, instead, may onlybe connected by bridging member 1240.

Similar to previously-discussed structural system, structural system1250 can be shiftable between a flat configuration, as shown in FIG. 50,and a folded configuration, as generally depicted in FIG. 51. When inthe flat configuration, structural system 1250 includes a plurality ofgaps 1270 a-g defined between opposing surfaces of adjacent substrates1252 a-h. In the embodiment shown in FIG. 50, the opposing surfaces ofadjacent substrates 1252 a-h may be angularly oriented with respect toone another and may also be at least partially coated with coatingmaterial 1256. When shifted to the folded configuration, at least onedimension of at least a portion of gaps 1270 a-g may change and, asshown in the embodiment depicted in FIG. 51, gaps 1270 a-g may contractwhen structural system 1250 is shifted to the folded configuration. Oncein the folded configuration, structural system 1250 may have a generallyrounded or arcuate shape, making it particularly suitable for use inconstruction applications, particularly those for curved walls orsurfaces.

Referring now to FIGS. 52 and 53, still another embodiment of anextrusion-coated structural system 1300 is illustrated as comprising apair of substrates 1312, 1314 and a coating material 1316 extrusioncoated onto at least a portion of substrates 1312 and 1314.Additionally, structural system 1300 comprises a pair of bridgingmembers 1340, 1342 extending from at least a portion of one substrate1312 to at least a portion of the other substrate 1314. Bridging members1340, 1342 are formed of coating material 1316, which may, in oneembodiment, be continuous with at least a portion of the coatingmaterial 1316 coated onto substrates 1312 and 1314. As illustrated inthe embodiment depicted in FIGS. 52 and 53, bridging member 1340 may bethe only connection member between substrates 1312 and 1314.

As shown in the embodiment depicted in FIGS. 52 and 53, substrates 1312and 1314 may be spaced apart from one another to form a gap 1344 acrosswhich bridging member 1340 and 1342 may at least partially extend. Inone embodiment, structural system 1300 may be shiftable between anextended configuration, as shown in FIG. 53, and a contractedconfiguration, as generally shown in FIG. 52. When arranged in anextended configuration, gap 1344 between substrates 1312 and 1314 isgreater than when structural system 1300 is arranged in a contractedconfiguration. At least a portion of the transition between an extendedand a contracted configuration may folding or bending at least one ofbridging member 1340 and 1342 to reduce at least one dimension of gap1344, as shown in FIG. 52.

In one embodiment, at least one functional element (not shown), such as,for example, piping, electrical conduit, wires, cables, lightingelements or fixtures, and combinations thereof, may be inserted into gap1344 when structural system 1300 is in an extended configuration shownin FIG. 53, and thereafter, system 1300 may be shifted to a retractedconfiguration, as depicted in FIG. 52, to hold, support, or just hidethe functional element within gap 1344. In one embodiment, structuralsystem 1300 may be particularly useful in as a furniture component or aconstruction material. In addition to enhancing the aesthetics of theultimate article or material, structural system 1300 may also provideadditional functionality as a holding device for a variety of functionalelements.

Turning now to FIGS. 54-56, one embodiment of an extrusion-coatedstructural system 1350 is shown as comprising a plurality of substrates1352, 1354, and 1356 and a coating material 1358 extrusion coated ontoat least a portion of substrates 1352, 1354, 1356. Structural system1350 further includes a bridging member 1370 extending between at leasta portion of substrate 1352 and 1354 and a bridging member 1372extending between at least a portion of substrate 1354 and 1356. Asshown in FIGS. 54-56, substrates 1352, 1354, and 1356 of structuralsystem 1350 are arranged in a nested configuration, with at least aportion of substrates 1352 and 1354 being at least partially disposedwithin a cavity 1382 at least partially defined by substrate 1356 and/orsubstrate 1352 being at least partially disposed within a cavity 1384defined by substrate 1354. In one embodiment, substrates 1352, 1354,1356 may be formed by simultaneously extrusion coating separatesubstrates to form structural system 1350, while, in another embodiment,each of substrates 1352, 1354, 1356 may be cut from a single substratewhich has been extrusion coated.

Structural system 1350 can be configured to be shifted between a flatconfiguration, shown in FIG. 53, to at least one extended configuration,shown in FIGS. 54 and 55 using bridging members 1370 and/or 1372. Toshift structural system 1350 from a flat configuration, as shown in FIG.53, to an assembled configuration, as shown in FIGS. 54 and 55, bridgingmembers 1370 and/or 1372 may be bent, rotated, or otherwise flexed sothat the position of one of substrates 1352, 1354, and/or 1356 may bechanged relative to at least one other of substrates 1352, 1354, 1356,without decoupling the substrates 1352, 1354, 1356 from one another. Inone embodiment shown in FIGS. 53-55, one of bridging member 1370 may beconfigured to rotate, move, bend, or flex in a different direction thanthe other bridging member 1372, such that one or more of substrates1352, 1354, and 1356 may move in a direction other than the direction inwhich one or more of the other substrates 1352, 1354, and 1356 areconfigured to move. In one embodiment, structural systems configured ina similar manner to structural system 1350 may be particularly usefulfor furniture or cabinetry applications, including, for example, inmodular furniture applications. In addition to being simpler toassemble, such structural system may also be simpler and/or lessexpensive to manufacture and ship than similar conventional items.

Turning now to FIGS. 57-59, a further embodiment of an extrusion-coatedstructural system 1400 is illustrated as comprising a plurality ofsubstrates 1412, 1414, 1416 and a coating material extrusion coated ontoat least a portion of substrates 1412, 1416, and 1418. As shown in FIGS.57-59, structural system 1400 also includes at least one bridging member1440 extending between at least a portion of two or more of substrates1412, 1414, 1416. In one embodiment, substrates 1412, 1414, 1416 mayhave been formed by cutting a pair of gaps 1420, 1422 at spaced-apartlocations along the length of a single extrusion coated substrate. Asshown in FIG. 57, each of gaps 1420 and 1422 may include uncoatedopposing surfaces 1434 a, b and 1436 a, b angularly oriented withrespect to each other. Optionally, one or both of opposing surfaces 1434a, b and/or 1436 a, b may include an adhesive material (not shown) tofurther secure structural system 1400 in a desired end configuration.

According to one embodiment shown in FIG. 57, the position of one ormore of substrates 1412, 1414, 1416 may be adjusted relative to theposition of one or more other substrates 1412, 1414, 1416 by rotating,bending, flexing, or otherwise moving bridging member 1440. For example,structural system 1400 may be shifted between a flat position, as shownby the solid lines in FIG. 57, to a folded configuration, shown by thedashed lines in FIG. 57 and the solid lines in FIG. 58, by movingsubstrates 1412 and 1416 along a path of motion represented by arrows1447 and 1449. Once substrates 1412, 1414, 1416 are assembled into afolded configuration shown in FIG. 58, a hardware member, shown as panel1436, may be inserted into a structural recess 1438 collectively definedby substrates 1412, 1414, 1416. The resulting configuration ofstructural system 1450, shown in FIG. 59, may be used in a variety offurniture or cabinetry applications. Additionally, one or moreadditional hardware members (not shown), such a shelves and shelfsupports, hinges, slides, and the like may also be included instructural system 1450, depending on its specific end use. In oneembodiment, structural system 1450 can be used as a cabinet box, adrawer, a shelf, a dresser, or any other suitable item.

Several extrusion-coated structural systems configured according toembodiments of the present invention have been discussed in detailabove. Although one or more features of these systems may have only beendescribed with reference to one or a few of the embodiments illustratedin the Figures, it should be understood that the particular embodimentsdescribed above are exemplary and one or more features described withrespect to one embodiment above could be used in a structural systemconfigured according to another embodiment and still fall within thescope of the present invention. Similarly, one or more features ofstructural system described above could be combined to form anotherstructural system not particularly illustrated without departing fromthe spirit of the present invention.

In another aspect, the present invention relates to methods ofassembling one or more of the extrusion-coated structural systemsdescribed in detail above. For example, in one embodiment, one or morestructural systems of the present invention may be assembled bycontacting at least a portion of one structural member with anotherstructural member to form at least a portion of the structural system.In one embodiment, the contacting can include joining one structuralmember to another by, for example, inserting a hardware protrusion intoa structural recess so that the hardware protrusion is at leastpartially supported by at least a portion of a recess attachment surfaceand/or inserting a structural protrusion into a hardware recess so thatthe protrusion attachment surface is at least partially supported by atleast a portion of the hardware recess. In one embodiment, at least oneof the structural members is a reinforced structural member including areinforced region proximate the location where the structural membersare joined. The action of inserting the protrusion into the recess mayinclude, for example, sliding, rotating, or snapping a protrusion intoits corresponding recess, and the protrusion, once inserted, may beconfigured for movement within the recess as discussed in detailpreviously.

In another embodiment, the contacting can include contacting at least aportion of a structural member with one or more extruded profile membersof a second substrate, as discussed in detail previously. In oneembodiment wherein the extruded profile member includes a profilerecess, the contacting can include inserting a hardware, structural, orprofile protrusion into the profile recess, while, in anotherembodiment, the contacting can include inserting a profile protrusiondefined by the extruded profile member into a structural, profile, orhardware recess. Subsequent to the contacting, at least one hardwaremember, or an adhesive material, may be used to secure the structuralmember in a desired configuration.

Assembly of an extrusion-coated structural system can also includeadjustment of the position of one or more structural member relative toone or more other structural members and, may, for example, be doneusing a bridging member. When the structural system comprises a bridgingmember, the adjustment of the relative position of one or moresubstrates can be accomplished without decoupling the substrates and maybe accomplished within the an angular range of motion as describedpreviously.

Once assembled, the structural system of the present invention mayremain assembled or, in one embodiment, at least a portion, or all, ofthe structural system may be disassembled. Disassembly can generally becarried out by repeating the steps of assembly in reverse and mayinclude, for example, re-adjustment of the positions of one or moresubstrates, removal of a hardware or profile protrusion from astructural recess, removal of a structural protrusion from a hardware orprofile recess, and/or breaking of contact between two or moresubstrates. When disassembled, structural systems of the presentinvention exhibit little or no damage to the component parts, and insome cases, such as structural systems including at least one bridgingmember, the substrates may not be uncoupled during disassembly.

Once disassembled, the components can be shipped or stored in adisassembled state and/or may be reassembled at a different time,sometimes in a slightly different configuration. For example, in oneembodiment, the structural system of the present invention can includeat least one adjustable component, configured to be arranged within thestructural system in more than one position. In one embodiment, this mayinclude a structural member having multiple hardware insertion points ora structural member having an extruded profile member configured tocontact more than one additional structural member. The flexibility ofdesign, along with the ability for repeated use may be unique andbeneficial features of the extrusion-coated structural systems of thepresent invention.

In another aspect, the present invention relates to methods of makingextrusion-coated structural systems, including the extrusion-coatedstructural systems described above. In one embodiment, the method ofmaking one or more of the extrusion-coated structural systems orextrusion-coated structural members of the present invention can includeextrusion coating at least one coating material onto at least a portionof one or more substrates. As discussed previously, the term “extrusioncoating” refers to a process for applying a fluid coating material ontoat least a portion of a substrate, optionally under pressure and/or atan elevated temperature. As used herein, the term “extrusion coating”can include applying different thickness of coating to different regionsof the substrate and also encompasses the formation of one or moreextruded profile members extending outwardly from the substrate, whetheror not the profile member includes underlying substrate. Further detailsregarding the methods for making extrusion-coated structural membersaccording to embodiments of the present invention will be discussed indetail below, with reference to FIG. 60.

Referring now to FIG. 60, a schematic flow diagram of an extrusioncoating system 1512 configured according to one embodiment of thepresent invention is provided. Coating system 1512 is illustrated ascomprising a pretreatment zone 1514, a drying zone 1516, an optionalstaging area 1518, an extrusion coating die 1520, a quench zone 1522,and an optional post treatment zone 1524. As shown in FIG. 60, one ormore substrates can be sequentially passed through pretreatment zone1514, drying zone 1516, and optional staging area 1518 before beingintroduced into extrusion coating die 1520, which is configured tofacilitate contact between at least a portion of the surface of thesubstrate or substrates and at least one coating material introducedinto die 1520 from a coating source 1530. The resulting coated articlecan be cooled in quench zone 1522 before being optionally treated in apost treatment zone 1524. If not further processed in post-treatment inzone 1524, the cooled, coated substrate may simply be removed fromcoating system 1512, as indicated by line 1526.

Coating system 1512 can be configured to process any substrate capableof being extrusion coated and suitable for use in extrusion-coatedstructural systems according to embodiments of the present invention.The substrates used may be rigid or substantially rigid substrates andcan have any suitable dimensions. According to one embodiment, thesubstrate being coated for use in one or more extrusion-coatedstructural systems described above may have a length, or largestdimension, of at least about 5 feet, at least about 6 feet, at leastabout 8 feet, at least about 10 feet, at least about 12 feet and/or notmore than about 25 feet, not more than about 20 feet, or not more thanabout 15 feet. In the same or another embodiment, the substrate can havea length in the range of from about 5 feet to about 25 feet, about 8feet to about 20 feet, or about 10 feet to about 15 feet. The substratecan also have a width, or second largest dimension, of at least about 1inch, at least about 2 inches, or at least about 4 inches and/or notmore than about 10 inches, not more than about 8 inches, or not morethan about 6 inches, or in the range of from about 1 to about 10 inches,about 2 to about 8 inches, or about 4 to about 6 inches. The thickness,or shortest dimension, of the substrate being coated in coating system1512 can be at least about 0.10 inches, at least about 0.25 inches, atleast about 0.5 inches and/or not more than about 4 inches, not morethan about 2 inches, or not more than about 1 inch, or in the range offrom about 0.10 to about 4 inches, about 0.25 to about 2 inches, orabout 0.5 to about 1 inch.

Substrates being extrusion coated in coating system 1512 and suitablefor use in the extrusion-coated structural system described herein madeof a variety of substrate materials. In one embodiment, the substratescoated in coating system 1512 can comprise a single material, while, inanother embodiment, the substrate can be a composite of two or moredifferent materials. Examples of suitable materials can be one or moreof natural wood, wood composites, plastics including cellularized PVCand other foams, metal, fiberglass-reinforced thermoset or thermoplasticpolymers, ceramics, cement, and combinations thereof. In the same oranother embodiment, the substrate material comprises medium-densityfiber board (MDF), particle board, oriented strand board (OSB),high-density fiberboard (HDF), wood-filled plastic, wood-plasticcomposites, ultra-light density fiber board (LDF), plywood, andcombinations thereof.

The coating material applied to the substrate in coating system 1512 canbe any coating material exhibiting sufficient processability andadhesion to the selected substrate. In one embodiment, the coatingmaterial may have an elongation at break, as measured by ASTM D882, ofat least about 1 percent, at least about 5 percent, at least about 10percent, at least about 25 percent, at least about 40 percent, at leastabout 55 percent, at least about 70 percent and/or not more than about250 percent, not more than about 200 percent, not more than about 150percent, or not more than 100 percent.

The elongation at break of the coating material used in one or moreembodiments described herein may be in the range of from about 1 toabout 250 percent, about 1 to about 200 percent, about 1 to about 150percent, about 1 to about 100 percent, about 5 to about 250 percent,about 5 to about 200 percent, about 5 to about 150 percent, about 5 toabout 100 percent, about 10 to about 250 percent, about 10 to about 200percent, about 10 to about 150 percent, about 10 to about 100 percent,about 25 to about 250 percent, about 25 to about 200 percent, about 25to about 150 percent, about 25 to about 100 percent, about 40 to about250 percent, about 40 to about 200 percent, about 40 to about 150percent, about 40 to about 100 percent, about 55 to about 250 percent,about 55 to about 200 percent, about 55 to about 150 percent, about 55to about 100 percent, about 70 to about 250 percent, about 70 to about200 percent, about 70 to about 150 percent, about 70 to about 100percent.

The coating material can have a yield stress of at least about 5 MPa, atleast about 10 MPa, at least about 15 MPa, at least about 20 MPa, atleast about 25 MPa and/or not more than about 50 MPa, not more thanabout 45 MPa, not more than about 40 MPa, or not more than about 35 MPa,measured according to the procedure provided in ASTM D882. The yieldstress of the coating material used in one or more embodiments describedherein can be in the range of from about 5 to about 50 MPa, about 5 toabout 45 MPa, about 5 to about 40 MPa, about 5 to about 35 MPa, about 10to about 50 MPa, about 10 to about 45 MPa, about 10 to about 40 MPa,about 10 to about 35 MPa, about 15 to about 50 MPa, about 15 to about 45MPa, about 15 to about 40 MPa, about 15 to about 35 MPa, about 20 toabout 50 MPa, about 20 to about 45 MPa, about 20 to about 40 MPa, about20 to about 35 MPa, about 25 to about 50 MPa, about 25 to about 45 MPa,about 25 to about 40 MPa, about 25 to about 35 MPa. This may be incontrast, for example, to conventional coatings like paints, which havea yield stress of less than 1 MPa.

The coating material can also have a percent yield strain of at leastabout 1 percent, at least about 2 percent, at least about 5 percentand/or not more than about 8 percent, not more than about 6 percent, ascalculated by ASTM D882. This may be, in some cases, lower thanconventional coatings, such a paint, which may exhibit a percent yieldstrain greater than 9 percent. The coating material used herein may alsohave a modulus of at least about 10 MPa, at least about 50 MPa, at leastabout 100 MPa, at least about 500 MPa, at least about 1000 MPa, at leastabout 1200 MPa and/or not more than about 2500 MPa, not more than about2000 MPa, not more than about 1500 MPa, measured according to ASTM D882.The modulus of the coating material can be in the range of from about 10to about 2500 MPa, about 10 to about 2000 MPa, about 10 to about 1500MPa, about 50 to about 2500 MPa, about 50 to about 2000 MPa, about 50 toabout 1500 MPa, about 100 to about 2500 MPa, about 100 to about 2000MPa, about 100 to about 1500 MPa, about 500 to about 2500 MPa, about 500to about 2000 MPa, about 500 to about 1500 MPa, about 1000 to about 2500MPa, about 1000 to about 2000 MPa, about 1000 to about 1500 MPa, about1200 to about 2500 MPa, about 1200 to about 2000 MPa, about 1200 toabout 1500 MPa.

The coating material may comprise one or more polymers or resins, suchas thermoplastic polymers or resins capable of being applied to thesubstrate in a molten or melted form. The coating material may be aresin coating comprising at least one thermoplastic and/or at least onethermosetting resin. In one embodiment, the resin can be present in thecoating material in an amount of at least about 30 weight percent, atleast about 40 weight percent, at least about 50 weight percent, atleast about 60 weight percent and/or not more than about 99 weightpercent, not more than about 90 weight percent, not more than about 85weight percent, based on the total weight of the composition.

Suitable thermoplastic resins can be those having one or more propertieswithin certain ranges. For example, in one embodiment, the thermoplasticresin employed in the coating material extrusion coated onto thesubstrate may have a glass transition temperature of at least about 60°C., at least about 70° C., at least about 80° C. and/or not more thanabout 150° C., not more than about 140° C., or not more than about 130°C. The glass transition temperature can be in the range of from about 60to about 150° C., about 60 to about 140° C., about 60 to about 130° C.,about 70 to about 150° C., about 70 to about 140° C., about 70 to about130° C., about 80 to about 150° C., about 80 to about 140° C., about 80to about 130° C.

In the same or another embodiment, the thermoplastic resin can have aninherent viscosity (I.V.), measured at 25° C. in 60/40 wt/wtphenol/tetrachloroethane, of at least about 0.50, at least about 0.65,at least about 0.69 dL/g and/or not more than about 1.4, not more thanabout 1.2, not more than about 1.0, not more than about 0.9, not morethan about 0.85 dL/g, or in the range of from about 0.50 to about 1.4dL/g, about 0.50 to about 1.2 dL/g, about 0.50 to about 1.0 dL/g, about0.50 to about 0.9 dL/g, about 0.50 to about 0.85 dL/g, about 0.65 toabout 1.4 dL/g, about 0.65 to about 1.2 dL/g, about 0.65 to about 1.0dL/g, about 0.65 to about 0.9 dL/g, about 0.65 to about 0.85 dL/g, about0.69 to about 1.4 dL/g, about 0.69 to about 1.2 dL/g, about 0.69 toabout 1.0 dL/g, about 0.69 to about 0.9 dL/g, about 0.69 to about 0.85dL/g.

In addition, the thermoplastic resin may be amorphous, crystalline, orsemi-crystalline and can have a crystallization half-time of at leastabout 5, at least about 50, at least about 100, at least about 1000, atleast about 10,000 minutes measured at 170° C. The crystallization halftime of the polyester, as used herein, may be measured using methodswell-known to persons of skill in the art. The crystallization half timeof the polyester, t_(1/2), was determined by measuring the lighttransmission of a sample via a laser and photo detector as a function oftime on a temperature controlled hot stage. This measurement was done byexposing the polymers to a temperature, T_(max), and then cooling it tothe desired temperature. The sample was then held at the desiredtemperature by a hot stage while transmission measurements were made asa function of time. Initially, the sample was visually clear with highlight transmission and became opaque as the sample crystallizes. Thecrystallization half-time is the time at which the light transmissionwas halfway between the initial transmission and the final transmission.T_(max) is defined as the temperature required to melt the crystallinedomains of the sample (if crystalline domains are present). The sampleis heated to Tmax to condition the sample prior to crystallization halftime measurement. The absolute Tmax temperature is different for eachcomposition.

The thermoplastic resin utilized in the coating material may be chosenfrom linear thermoplastic resins, branched thermoplastic resins,hyperbranched thermoplastic resins, and star-shaped thermoplasticresins. Non-limiting examples of suitable thermoplastic resins includepolyesters, copolyesters, acrylics, polycarbonates and mixtures thereof.Additional non-limiting examples include poly(ethylene terephthalate)(PET), PETG copolyester, poly(methyl methacrylate) (PMMA),poly(acrylonitrile-styrene-acrylate) (ASA),poly(acrylonitrile-butadiene-styrene) (ABS), poly(styrene-acrylonitrile)(SAN) and mixtures thereof. Examples of thermoplastic resins include,but are not limited to, EASTAR copolyester 6763, a PETG available fromEastman Chemical Company; LURAN HD, a SAN available from BASF; TERLURANGP-22, an ABS available from BASF; Modified Acrylate, a PMMA availablefrom Degussa; and CENTREX 833, an ASA available from Lanxess. In oneembodiment, the thermoplastic resin used in the coating material can beselected from the group consisting of polyesters, copolyesters,polycarbonates, polymethyl methacrylate (PMMA), includingimpact-modified PMMA, poly(acrylonitrile-styrene-acrylate) (ASA),poly(acrylonitrile-butadiene-styrene) (ABS), poly(styrene-acrylonitrile)(SAN), cellulose esters and mixtures thereof. According to oneembodiment, the resin coating can include a copolyester comprising atleast 80 mole percent of acid residues from terephthalic acid,derivatives of terephthalic acid and mixtures thereof, at least 80 molepercent of glycol residues from ethylene glycol and1,4-cyclohexanedimethanol, wherein the acid residues are based on 100mole percent of acid residues and the glycol residues are based on 100mole percent of glycol residues.

According to another embodiment, the coating material can comprise atleast one polyester that includes 70 to 100 mole percent acid residuesfrom terephthalic acid, 0 to 30 mole percent aromatic dicarboxylic acidresidues having up to 20 carbon atoms, and 0 to 10 mole percent ofaliphatic dicarboxylic acid residues having up to 16 carbon atomswherein the acid residues are based on 100 mole percent acid residue.The resin coating could also comprise a polyester comprising 80 to 100mole percent acid residues from terephthalic acid, 0 to 20 mole percentaromatic dicarboxylic acid residues having up to 20 carbon atoms, and 0to 10 mole percent of aliphatic dicarboxylic acid residues having up to16 carbon atoms wherein the acid residues are based on 100 mole percentacid residues. In another embodiment, the resin coating can comprise apolyester comprising 90 to 100 mole percent acid residues fromterephthalic acid, 0 to 10 mole percent aromatic dicarboxylic acidresidues having up to 20 carbon atoms, and 0 to 10 mole percent ofaliphatic dicarboxylic acid residues having up to 16 carbon atomswherein the acid residues are based on 100 mole percent acid residues.

In addition to the resin component, the coating material may alsoinclude one or more additional components, including, for example, atleast one opacity modifier, at least one gloss modifier, at least oneimpact modifier, and combinations thereof. When included, the opacitymodifier can be present in the coating material in an amount of at leastabout 0.5 percent, at least about 1 percent, at least about 2 percentand/or not more than about 20 percent, not more than about 15 percent,not more than about 10 percent, based on the total weight of the coatingmaterial. The opacity modifier can be present in the coating material inan amount in the range of from about 0.05 to about 20 percent, about0.05 to about 15 percent, about 0.05 to about 10 percent, about 1 toabout 20 percent, about 1 to about 15 percent, about 1 to about 10percent, about 2 to about 20 percent, about 2 to about 15 percent, about2 to about 20 percent, based on the total weight of the coatingmaterial. Non-limiting examples of suitable opacity modifiers includemetal oxides and metal salts, such as, for example, zinc oxide (ZnO),mica, white lead, barium sulfate (BaSO₄), zinc sulfide (ZnS), antimonyoxide and titanium dioxide (TiO₂).

In the same or another embodiment, the coating material can include atleast about 1, at least about 5, at least about 10 and/or not more thanabout 50, not more than about 40, not more than about 30 weight percent,based on the total weight of the coating material, of one or more glossmodifiers. The coating material can include gloss modifiers in an amountin the range of from about 1 to about 50 percent, about 1 to about 40percent, about 1 to about 30 percent, 5 to about 50 percent, about 5 toabout 40 percent, about 5 to about 30 percent, 10 to about 50 percent,about 10 to about 40 percent, about 10 to about 30 percent, based on thetotal weight of the coating material.

Non-limiting examples of suitable inorganic fillers include talc(magnesium silicate), silica, kaolin clay, alumina and calcium carbonate(CaCO₃). Examples of polymeric fillers include, but are not limited to,BLENDEX BMAT (a cross-linked styrene acrylonitrile in a polystyrenematrix) available from Chemtura and Galata Chemicals, ECDEL elastomersavailable from Eastman Chemical Company and PARALOID KM-377 (an acrylatepolymer) available from Rohm and Haas and The Dow Chemical Company.

Additionally, in one embodiment, the coating material can furtherinclude at least one impact modifier present in the coating material inan amount of at least about 0.5 percent, at least about 1 percent, atleast about 2 percent and/or not more than about 20 percent, not morethan about 15 percent, not more than about 10 percent, based on thetotal weight of the coating material. The impact modifier may be presentin the coating composition in an amount in the range of from about 0.5to about 20 percent, about 0.5 to about 15 percent, about 0.5 to about10 percent, about 1 to about 20 percent, about 1 to about 15 percent,about 1 to about 10 percent, about 2 to about 20 percent, about 2 toabout 15 percent, about 2 to about 10 percent, based on the total weightof the coating composition. Non-limiting examples of the at least oneimpact modifier include polymers based on a polyolefin rubbery segment,sometimes also referred to as a rubbery phase, polymers based on apolyether rubbery phase, polymers based on an acrylic rubbery phase andpolymers based on a butadiene and/or isoprene rubbery phase. In anembodiment, the at least one impact modifier is chosen frompoly(acrylonitrile butadiene styrene) (ABS) polymers.

In addition, in one embodiment, one or more other application-specificadditives could also be used. Such additional additives may include, butare not limited to, gloss modifiers, opacity modifiers, impactmodifiers, adhesion modifiers, pigments, flame retardants, UV absorbers,antioxidants, colorants, and optical brighteners. Generally, forpolymeric formulations that are to be used as primers, an opaque whitecoloring is desired. Titanium dioxide a widely used white pigment, but avariety of other metal oxides and salts may be used. The amount of theadditive or additives employed in the coating material can vary, and, inone embodiment, can be at least about 0.01 weight percent, at leastabout 0.5 weight percent, at least about 0.75 weight percent and/or notmore than about 5 weigh percent, not more than about 2.5 weight percent,or not more than about 1 weight percent, based on the total weight ofthe coating composition. The total amount of additives present in saidcoating composition can be in the range of from about 0.01 to about 5weight percent, about 0.01 to about 2.5 weight percent, about 0.01 toabout 1 weight percent, about 0.5 to about 5 weight percent, about 0.5to about 2.5 weight percent, about 0.5 to about 1 weight percent, about0.75 to about 5 weight percent, about 0.75 to about 2.5 weight percent,about 0.75 to about 1 weight percent, based on the total weight of thecoating material.

Referring back to FIG. 60, the substrate can initially be introducedinto a pretreatment zone 1514, which can comprise one or more stagesconfigured to prepare the substrate for coating. For example,pretreatment zone 1514 can include one or more milling stages forforming an initial blank stock, or precursor, substrate into a substratehaving a desired shape by milling and/or cutting the substrate to adesired profile and/or length. In another embodiment, one or morerecesses or cavities may also be cut into the precursor substrate tothereby provide a substrate ready for extrusion coating.

Optionally, pretreatment zone 1514 may also comprise at least onecleaning stage for removing particles of dirt, dust, or other debrisfrom the surface of the substrate before coating. The cleaning stage maycomprise a high pressure steam cleaning, a high pressure air cleaning, asolvent cleaning, a water bath cleaning, and/or any other cleaningprocess appropriate for the particular type of substrate employed incoating system 1512. In one embodiment, pretreatment zone 1514 mayinclude a stain bath for staining at least a portion of the substrateprior to coating.

Following pretreatment, the substrate can then be introduced into dryingzone 1516, wherein at least a portion of the surface of the substratemay be heated to thereby facilitate removal of at least some of thevolatile materials within the substrate, if present. Once removed fromdrying zone 1516, the substrate can pass through optional staging area1518 before being introduced into die 1520 via a feed system 1528, whichmay be configured to properly align the one or more substrates beingcoated with at least one inlet of die 1520 (not shown).

In one embodiment, feed system 1528 can comprise a plurality of rollers,positioned above and below the substrate (not shown), which areconfigured to engage and push the substrate or substrates into die 1520.Feed system 1528 may be configured to supply one or more substrates intodie 1520 in a substantially continuous manner, such that, for example,the individual substrate members are fed to the die 1520 in abutt-to-butt manner, where contact is maintained between the back end ofa first substrate member and the front end of a second substrate memberfed behind the first substrate member. According to another embodiment,two substrates may be fed into die 1520 spaced apart from one anotherand the space between the substrates may be maintained during thecoating process.

As the substrate is introduced into die 1520, at least a portion of thesurface of the substrate can be contacted with a coating materialintroduced into die 1520 from coating source 1530. Coating source 1530can be any suitable system or apparatus for providing a coating, and, inone embodiment, may be an extruder. The temperature in the die 1520during the coating process can be any temperature sufficient to maintainthe incoming coating material in a liquid or substantially liquid state.In one embodiment, the temperature in die 1520 during coating can be atleast about 50° C., at least about 100° C., at least about 200° C.and/or not more than about 500° C., not more than about 400° C., notmore than about 300° C., or in the range of from about 50 to about 500°C., about 50 to about 400° C., about 50 to about 300° C., about 100 toabout 500° C., about 100 to about 400° C., about 100 to about 300° C.,about 200 to about 500° C., about 200 to about 400° C., about 200 toabout 300° C. The pressure in die 1520 during the coating step can be atleast about 25 pounds per square inch (psi), at least about 50 psi, atleast about 100 psi and/or not more than about 5,000 psi, not more thanabout 3,500 psi, not more than about 2,000 psi, not more than about1,500 psi, not more than 1,000 psi, or in the range of from about 25 toabout 5,000 psi, about 25 to about 3,500 psi, about 25 to about 2,000psi, about 25 to about 1,500 psi, or about 25 to about 1,000 psi, about50 to about 5,000 psi, about 50 to about 3,500 psi, about 50 to about2,000 psi, about 50 to about 1,500 psi, or about 50 to about 1,000 psi,about 100 to about 5,000 psi, about 100 to about 3,500 psi, about 100 toabout 2,000 psi, about 100 to about 1,500 psi, or about 100 to about1,000 psi.

The coating may be applied to at least a portion, or substantially all,of the surface of the substrate such that at least about 50 percent, atleast about 65 percent, at least about 75 percent, at least about 85percent, or at least about 95 percent of the total surface area ofsubstrate is covered with a coating material. Thus, in one embodiment,one or more sides of an n sided substrate (wherein n is an integerbetween 3 and 10, inclusive) may be left partially or totally uncoated,such that n−1 sides are completely coated by the material. In anotherembodiment, the entirety of the outer surface of the substrate may becoated such that all sides of the substrate are completely encapsulatedby the coating material. The average thickness of the coating materialmay be in the ranges discussed previously.

When the substrate includes a structural recess and/or a structuralprotrusion as discussed previously, the extrusion coating step carriedout in die 1520 may include applying at least one coating material toone or more surfaces presented by the structural recess and/or thestructural protrusion, thereby forming the recess attachment orprotrusion attachment surfaces described above. In one embodiment, whenthe substrate includes a structural recess, the coating materialextruded onto the recess surface may be sufficient to at least partiallyfill the structural recess with coating material. For example, in oneembodiment, the maximum thickness of the coating material within thestructural recess may be at least 2 times greater than the thickness ofthe coating material forming the near recess external surface of theextrusion-coated structural member.

In one embodiment, a second coating material may be applied to at leasta portion of the substrate, including at least one recess and/orprotrusion surface, either by extrusion coating or any other suitablemethod. In one embodiment, the first and second coating materials can beapplied in an alternating or “striped” pattern, while, in anotherembodiment, at least a portion of one of the coating materials mayoverlap or be layered with the other. According to one embodiment, thesecond coating material may also be applied to the substrate byextrusion coating, simultaneous with, or subsequent to, application ofthe first coating material.

Referring back to FIG. 60, the extrusion coated structural memberexiting die 1520 may be routed to a cooling or quench zone 1522, whereinthe extrusion-coated structural member can be cooled via contact with acooling fluid. In one embodiment, the cooling performed in cooling orquench zone 1522 may be sufficient to reduce the surface temperature ofthe coated substrate by at least about 5° C., at least about 10° C., atleast about 15° C., at least about 20° C., at least about 25° C., or atleast about 30° C. Examples of suitable cooling fluids can include air,an inert gas, and/or water and quench zone 1522 may or may not have apressure greater than atmospheric. Subsequent to quench zone 1522, thecooled extrusion-coated structural member can be optionally sent to apost-treatment zone 1524, wherein one or more additional processingand/or treatment steps may be carried out. In one embodiment,post-treatment zone 1524 can employ one or more processes to alter atleast one property of the extrusion-coated structural member and mayalso include other post-coating treatments such as milling, cutting, oreven assembling and/or packaging.

According to one embodiment of the present invention, structural membersas described herein may exhibit enhanced properties or characteristicsas compared to similarly-configured, but uncoated orconventionally-coated (e.g., painted), substrates. For example, in somecases, application of one or more coating materials as described hereinto a substrate that comprises at least one protrusion may result in astructural member having increased strength and/or durability, and whichmay be less likely to crack or fail during use.

Turning now to FIGS. 61-63, one example of a structural system 1750 thatincludes a pair of structural members 1752 and 1762 configured accordingto an embodiment of the present invention is provided. Althoughillustrated in FIGS. 61-63 as including only a first structural member1752 and a second structural member 1762, it should be understood thatstructural system 1750 can include any suitable number of structuralmembers, including, for example, at least about 2 structural members, atleast about 5 structural members, at least about 10 structural members,and/or not more than about 100 structural members, not more than about75 structural members, not more than about 50 structural members, or notmore than about 30 structural members. When more than two structuralmembers are employed in structural system 1750, one or both ofstructural members 1752 and 1762 may have additional protrusions and/orrecesses configured to be inserted into one or more other recessesand/or configured to receive one or more other protrusions of the otherstructural members, not shown in FIGS. 61-63.

Additionally, although represented being configured similarly tostructural system 1650 depicted in FIGS. 22 and 23, it should also beunderstood that enhanced properties as described in further detail belowmay also be present in a variety of other structural systems configuredaccording to aspects of the present invention, including one or more ofthe structural systems described in detail previously.

Turning again to FIGS. 61 and 62, each of structural members 1752 and1762 comprise a substrate 1754 and 1764 and a coating material 1756 and1766 coated onto at least a portion of respective substrates 1754 and1764. Although shown as being applied to all or nearly all of thesurface area of substrates 1754 and 1764, coating materials 1756 and/or1766 may, in some embodiments, coat only a portion of the surface areaof respective substrates 1754 and 1764.

In one embodiment, coating materials 1756 and/or 1766 may be applied to(coated onto) at least about 50 percent, at least about 60 percent, atleast about 70 percent, at least about 80 percent, at least about 90percent, at least about 95 percent, or at least about 99 percent of thetotal surface area of substrates 1754 and/or 1764. Coating materials1756 and/or 1766 may extend continuously around at least three, at leastfour, or all sides of at least one cross-section of substrates 1754and/or 1764. In some cases, all or nearly all of the surface area ofsubstrates 1754 and/or 1764 may be coated so that, for example, lessthan about 10 percent, less than about 5 percent, less than about 2percent, less than about 1 percent of the total surface area ofsubstrates 1754 and/or 1764 is not coated with the coating material.

Coating materials 1756 and 1766 can be applied to respective first andsecond substrates 1754 and 1764 according to any suitable method. In oneembodiment, at least one of structural members 1752 and 1762 can beextrusion-coated structural members and at least a portion of coatingmaterials 1756 and 1766 can be extrusion coated onto one or moresurfaces of substrates 1754 and 1764. According to another embodiment,coating materials 1756 and 1766 may be applied to substrates 1754 and1764 in another manner, such as, for example, by injection molding,curtain coating, or other suitable method. The average thickness ofcoating material 1756 and/or 1766 applied to respective substrates 1754and/or 1764 may lie within the ranges described in detail previously.

Coating materials 1756 and 1766 can comprise any of the coatingmaterials described in detail previously. Coating material 1756 appliedto substrates 1754 may be the same as, or different than, coatingmaterial 1766 applied to substrate 1764. In one embodiment, coatingmaterials 1756 and/or 1766 can comprise at least one resin, which may bea thermoplastic or thermosetting resin. Exemplary resins include, butare not limited to, those selected from the group consisting ofpolyesters, acrylics, cellulose esters, nylons, polyolefins, polyvinylchloride, acrylonitrile-butadiene-styrene (ABS) copolymers,styrene-acrylonitrile copolymers (SAN), other styrene-based polymers andcopolymers, polycarbonates, and combinations thereof. In addition to oneor more of the resins listed above, coating material 1756 and/or 1766can further include at least one other additive of the type and/or inthe amount described in detail previously.

Substrates 1754 and 1764 can comprise any suitable material, includingone or more of the materials described in detail previously. Substrates1754 and/or 1764 can be formed of the same material or may be formed ofdifferent materials, and any additional structural members (not shown inFIGS. 61 and 62) may also comprise the same or a different material thansubstrates 1754 and/or 1764. Additionally, one or both of substrates1754 and/or 1764 may be formed of two or more different materials. Inone embodiment, the average density of substrates 1754 and/or 1764 canbe at least about 30 lb/ft³, at least about 35 lb/ft³, at least about 40lb/ft³, at least about 45 lb/ft³ and/or not more than about 65 lb/ft³,not more than about 60 lb/ft³, not more than about 55 lb/ft³, not morethan about 50 lb/ft³.

In one embodiment, substrates 1754 and/or 1764 can comprise anon-natural wood material. As used herein, the term “non-natural woodmaterial” refers to any material that includes at least one componentother than natural wood. Examples of components other than natural woodcan include, but are not limited to, binders, adhesives, plastics, andother materials. Some non-natural wood substrates may include a woodcomposite (or engineered wood) material that comprises smaller bodies ofwood bound together by adhesive, plastic, or other binder material.Specific examples of wood composite materials include, but are notlimited to, medium density fiber board (MDF), high density fiberboard(HDF), particle board, oriented strand board (OSB), wood-filled plastic,wood-plastic composites, ultra-light density fiber board (LFB), plywood,and combinations thereof. Other types of non-natural wood materials maynot include wood fibers and may, for example, be selected from the groupconsisting of plastics, glass, metals, foams, fiberglass-reinforcedthermoset or thermoplastic polymers, and combinations thereof.

Substrates 1754 and 1764 may comprise a material selected from the groupconsisting of wood composites, plastics, foams, glass,fiberglass-reinforced thermoset or thermoplastic polymers, metal, andcombinations thereof or substrates 1754 and/or 1764 may comprise amaterial selected from the group consisting of wood composites,plastics, foams, fiberglass-reinforced thermoset or thermoplasticpolymers, and combinations thereof. Substrates 1754 and/or 1764 may alsocomprise a material selected from the group consisting of medium densityfiber board (MDF), high density fiberboard (HDF), particle board,oriented strand board (OSB), wood-filled plastic, wood-plasticcomposites, ultra-light density fiber board (LFB), plywood, plastic,fiberglass-reinforced thermoset or thermoplastic polymers, foam,cellularized PVC, and combinations thereof.

As shown in one embodiment depicted in FIGS. 61-63, substrate 1754includes a main body portion 1770 and at least one protrusion 1772extending outwardly from main body portion 1770. Although shown asincluding only one protrusion, it should be understood that substrate1754 may include any suitable number of protrusions, depending on thespecific configuration and end use of structural member 1752 and/orstructural system 1750. When substrate 1754 includes more than oneprotrusion, additional protrusions may be located on the same side, orone a different side, of main body portion 1770 than protrusion 1772shown in FIG. 61-63.

In one embodiment, the ratio of the maximum thickness of main bodyportion 1770, shown as dimension T₁ in FIG. 63, to the maximum thicknessof protrusion 1772, shown as dimension T₂ in FIG. 63, can be at leastabout 1.25:1, at least about 1.5:1, at least about 1.75:1 and/or notmore than about 5:1, not more than about 3:1, not more than about 2.5:1,not more than about 2:1. The ratio of the maximum thickness of main bodyportion 1770 to the maximum thickness of protrusion 1772 (T₁:T₂) can bein the range of from about 1.25:1 to about 5:1, about 1.25:1 to about3:1, about 1.25:1 to about 2.5:1, about 1.25:1 to about 2:1, about 1.5:1to about 5:1, about 1.5:1 to about 3:1, about 1.5:1 to about 2.5:1,about 1.5:1 to about 2:1, about 1.75:1 to about 5:1, about 1.75:1 toabout 3:1, about 1.75:1 to about 2.5:1, about 1.75:1 to about 2:1.

The maximum thickness of main body portion 1770 can at least about 0.10inches, at least about 0.50 inches, at least about 0.75 inches, at leastabout 1 inch and/or not more than about 3 inches, not more than about2.5 inches, not more than about 2 inches, not more than about 1.5 inchesand/or the maximum thickness of protrusion 1772 can be at least about0.10 inches, at least about 0.50 inches, at least about 0.75 inches,and/or not more than about 2.5 inches, not more than about 2 inches, notmore than about 1.5 inches. Main body portion 1770 can have a maximumthickness in the range of from about 0.10 to about 3 inches, about 0.10to about 2.5 inches, about 0.10 to about 2 inches, about 0.10 to about1.5 inches, about 0.50 to about 3 inches, about 0.50 to about 2.5inches, about 0.50 to about 2 inches, about 0.50 to about 1.5 inches,about 0.75 to about 3 inches, about 0.75 to about 2.5 inches, about 0.75to about 2 inches, about 0.75 to about 1.5 inches, about 1 to about 3inches, about 1 to about 2.5 inches, about 1 to about 2 inches, about 1to about 1.5 inches and/or protrusion 1772 can have a maximum thicknessin the range of from about 0.10 to about 2.5 inches, about 0.10 to about2 inches, about 0.10 to about 1.5 inches, about 0.50 to about 2.5inches, about 0.50 to about 2 inches, about 0.50 to about 1.5 inches,about 0.75 to about 2.5 inches, about 0.75 to about 2 inches, about 0.75to about 1.5 inches.

In one embodiment, protrusion 1772 can extend outwardly from main bodyportion 1770 for a maximum distance, shown as L₁ in FIG. 63, for adistance of at least about 0.10 inches, at least about 0.25 inches, atleast about 0.50 inches, at least about 1 inch, at least about 1.5inches and/or not more than about 5 inches, not more than about 3inches, not more than about 2.5 inches, not more than about 2 inches, orin the range of from about 0.10 to about 5 inches, about 0.10 to about 3inches, about 0.10 to about 2.5 inches, about 0.10 to about 2 inches,about 0.25 to about 5 inches, about 0.25 to about 3 inches, about 0.25to about 2.5 inches, about 0.25 to about 2 inches, about 0.50 to about 5inches, about 0.50 to about 3 inches, about 0.50 to about 2.5 inches,about 0.50 to about 2 inches, about 1 to about 5 inches, about 1 toabout 3 inches, about 1 to about 2.5 inches, about 1 to about 2 inches,about 1.5 to about 5 inches, about 1.5 to about 3 inches, about 1.5 toabout 2.5 inches, about 1.5 to about 2 inches.

The ratio of the maximum distance that protrusion 1772 extends outwardlyfrom main body portion 1770 (L₁) to the maximum thickness of protrusion1772 (T₂) can be at least about 0.10:1, at least about 0.50:1, at leastabout 1:1, at least about 1.1:1, at least about 1.25:1, at least about1.5:1 and/or not more than about 5:1, not more than about 3:1, not morethan about 2.5:1, not more than about 2:1. The ratio of the maximumdistance that protrusion 1772 extends outwardly from main body portion1770 to the maximum thickness of protrusion 1772 (L₁:T₂) can be in therange of from about 0.10:1 to about 5:1, about 0.10:1 to about 3:1,about 0.10:1 to about 2.5:1, about 0.10:1 to about 2:1, about 0.50:1 toabout 5:1, about 0.50:1 to about 3:1, about 0.50:1 to about 2.5:1, about0.50:1 to about 2:1, about 1:1 to about 5:1, about 1:1 to about 3:1,about 1:1 to about 2.5:1, about 1:1 to about 2:1, about 1.1:1 to about5:1, about 1.1:1 to about 3:1, about 1.1:1 to about 2.5:1, about 1.1:1to about 2:1, about 1.25:1 to about 5:1, about 1.25:1 to about 3:1,about 1.25:1 to about 2.5:1, about 1.25:1 to about 2:1.

The ratio of the maximum distance that protrusion 1772 extends outwardlyfrom main body portion 1770 (L₁) to the maximum thickness of main bodyportion (T₁) can be at least about 0.05:1, at least about 0.10:1, atleast about 0.25:1, at least about 0.50:1, at least about 0.75:1 and/ornot more than 3:1, not more than about 2.5:1, not more than about 2:1,not more than about 1.5:1, or in the range of from about 0.05:1 to about3:1, about 0.05:1 to about 2.5:1, about 0.05:1 to about 2:1, about0.05:1 to about 1.5:1, about 0.10:1 to about 3:1, about 0.10:1 to about2.5:1, about 0.10:1 to about 2:1, about 0.10:1 to about 1.5:1, about0.25:1 to about 3:1, about 0.25:1 to about 2.5:1, about 0.25:1 to about2:1, about 0.25:1 to about 1.5:1, about 0.50:1 to about 3:1, about0.50:1 to about 2.5:1, about 0.50:1 to about 2:1, about 0.50:1 to about1.5:1, about 0.75:1 to about 3:1, about 0.75:1 to about 2.5:1, about0.75:1 to about 2:1, about 0.75:1 to about 1.5:1.

As shown in FIGS. 61-63, second structural member 1762 may also includea main body portion 1780 and at least one protrusion 1784 a extendingoutwardly from main body portion 1780. According to one embodiment shownin FIGS. 61-63, second structural member 1762 may also comprise a secondprotrusion 1784 b also extending outwardly from main body portion 1780.Each of the dimensions and ratios discussed previously with respect tomain body portion 1770 and protrusion 1772 of first structural member1752 may also be applicable to main body potion 1780 and at least one ofprotrusions 1784 a and/or 1784 b of substrate 1764. Although shown asextending from main body portion 1780 for similar maximum distances,shown as L₂ for protrusion 1784 a and L₃ for protrusion 1784 b in FIG.63, one of the pair of protrusions 1784 a,b may extend outwardly frommain body portion 1780 for a different distance than the other. In oneembodiment, the ratio of the maximum distance that protrusion 1784 aextends outwardly from main body portion 1780 (L₂) to the maximumdistance that protrusion 1784 b extends outwardly from main body portion1780 (L₃) can be at least about 0.5:1, at least about 0.60:1, at leastabout 0.75:1, at least about 0.85:1, at least about 0.95:1 and/or notmore than about 0.99:1, not more than about 0.95:1, not more than about0.85:1, not more than about 0.75:1. Alternatively, the ratio of L₂ to L₃can be 1:1, as generally shown in FIG. 63.

In one embodiment, the pair of protrusions 1784 a and 1784 b extendingoutwardly from main body portion 1780 of substrate 1764 may at leastpartially define at least one recess 1782. Recess 1782 can have anysuitable dimensions and, in one embodiment, can be configured to receivea protrusion (such as protrusion 1772 of substrate 1754) to couplestructural members 1752 and 1762 to one another. Thus, in oneembodiment, the width of recess 1782, shown as dimension W_(R) in FIG.63, can be sufficient to permit protrusion 1772, having a maximumthickness T₂ to be inserted, or at least partially inserted, therein. Inone embodiment, the ratio of the maximum thickness of protrusion 1772 tothe width of recess 1782 can be at least about 0.75:1, at least about0.85:1, at least about 0.95:1 and/or not more than 0.99:1, not more thanabout 0.95:1, not more than about 0.90:1, or in the range of from about0.75:1 to about 0.99:1, about 0.75:1 to about 0.95:1, about 0.75:1 toabout 0.90:1, about 0.85:1 to about 0.99:1, about 0.85:1 to about0.95:1, about 0.85:1 to about 0.90:1, about 0.90:1 to about 0.99:1,about 0.90:1 to about 0.95:1.

The width of recess 1782 can be at least about 0.10 inches, at leastabout 0.50 inches, at least about 0.75 inches, and/or not more thanabout 2.5 inches, not more than about 2 inches, not more than about 1.5inches, or can be in the range of from about 0.10 to about 2.5 inches,about 0.10 to about 2 inches, about 0.10 to about 1.5 inches, about 0.50to about 2.5 inches, about 0.50 to about 2 inches, about 0.50 to about1.5 inches, about 0.75 to about 2.5 inches, about 0.75 to about 2inches, about 0.75 to about 1.5 inches. The ratio of the width of recess1782 to the maximum distance of the longer of protrusions 1784 a and1784 b (i.e., the greater of L₂ and L₃) can be at least about 0.25:1, atleast about 0.5:1, at least about 1:1, and/or not more than about 3:1,not more than about 2.5:1, not more than about 2:1, or about 0.25:1 toabout 3:1, about 0.25:1 to about 2.5:1, about 0.25:1 to about 2;1, orabout 0.5:1 to about 3:1, about 0.5:1 to about 2.5:1, about 0.5:1 toabout 2;1, or about 1:1 to about 3:1, about 1:1 to about 2.5:1, about1:1 to about 2;1.

Although shown as including a pair of protrusions 1784 a,b, it should beunderstood that substrate 1764 may include any suitable number ofadditional protrusions, depending on the specific configuration and enduse of structural member 1762 and/or structural system 1750. Whensubstrate 1764 includes additional protrusions, one or more additionalrecesses may also be defined. For example, substrate 1764 (and/orsubstrate 1754) may include N protrusions extending outwardly from mainbody portion 1780 (or main body portion 1770), wherein N is an integerbetween 1 and 10, between 2 and 8, or between 2 and 5. In anotherembodiment, N can be 1. When substrate 1764 and/or 1754 includes Nprotrusions, it may also comprise or define N−1 recesses between the Nprotrusions. In some cases, one or more of the protrusions may bedisposed on opposite sides of main body portion 1780 and/or 1770,thereby resulting in (N−2) or (N−3) recesses, depending on the specificconfiguration of structural member 1762 or 1752.

As particularly shown in FIG. 62, main body portion 1770 of substrate1754 can present at least one body surface 1773 and protrusion 1772 ofsubstrate 1754 can present at least one protrusion surface 1775, whichintersect to form a junction 1774 disposed between main body portion1770 and protrusion 1772. Similarly, main body portion 1780 of substrate1764 can present at least one body surface 1789 and each of protrusions1784 a and 1784 b can respectively present at least one protrusionsurface 1787 a and 1787 b, which each intersect with body surface 1789to form a pair of junctions 1788 a and 1788 b. Additionally, main bodyportion 1780 can present another body surface 1783 and at least one ofprotrusions 1784 a and 1784 b (shown in FIG. 62 as being protrusion 1784a) can present another protrusion surface 1785 with can intersect withbody surface 1783 to form another junction 1786. Alternatively, bodysurface 1783 and protrusion surface 1785 may lie in substantially thesame plane, thereby making junction 1786 substantially planar.

In one embodiment, it may be advantageous for at least a portion ofcoating material 1756 applied to substrate 1754 and/or at least aportion of coating material 1766 applied to substrate 1764 to at leastpartially cover at least one of junctions 1774 of substrate 1754, and/orone or more of junctions 1788 a, 1788 b, or 1786 of substrate 1764. Twoor more, three or more, or all of junctions 1774, 1786, 1788 a, and 1788b may be at least partially coated with coating material 1756 and/orcoating material 1766 such that at least a portion of the coatingmaterial 1756 and/or 1766 extends continuously between at least aportion of adjacent protrusion and body surfaces. For example, whenjunction 1744 is at least partially coated with coating material 1756,at least a portion of coating material 1756 can extend continuouslybetween protrusion surface 1775 and body surface 1773. Similarly, whenjunction 1786 is at least partially coated with coating material 1766,at least a portion of coating material 1766 may extend continuouslybetween protrusion surface 1785 and body surface 1783. Alternatively, atleast one of junctions 1774, 1788 a, 1788 b, and 1786 may not be coatedwith a coating material (embodiment not shown in FIGS. 61 and 62.)

According to one embodiment of the present invention, application ofcoating material to all or part of one or more junctions 1774, 1788 a,1788 b, and 1786 may increase the peak stress achievable by structuralmember 1752 and/or 1762, even when the structural member is made from anon-wood substrate as described above. In one embodiment, structuralmember 1752 and/or 1762 may exhibit enhanced peak stress tolerances,measured by, for example, the peak stress increase as compared to anidentically-configured, but uncoated substrate. For example, in oneembodiment, structural member 1752 and/or 1762 may exhibit a peak stressincrease, measured at the outer edge of protrusion 1772 and/or 1784 a orb, of at least about 50 percent, at least about 75 percent, at leastabout 90 percent, at least about 100 percent, at least about 125percent, at least about 150 percent, measured along the outer edge ofthe protrusion (i.e., measured in the outer configuration as shown inFIG. 65c ), as compared to an identically-configured but uncoatedsubstrate. The method for determining the peak stress increase of acoated substrate is described in Example 3, below.

As discussed previously, extrusion-coated structural systems of thepresent invention have a wide variety of applications including, forexample, as furniture or cabinetry items and/or in several indoor andoutdoor construction and building end uses. In one embodiment, one ormore extrusion-coated structural systems described herein may be used incabinetry applications as doors, side walls, drawers, cabinet boxes, andother similar components, and may be used in furniture applications asshelves, tables, desks, drawers, cabinets, chairs, and the like.Specific construction uses can include, but are not limited to, wallboard, floor board, trim, door jambs or casing, window jambs or casing,crown molding, chair railing, frames, mantels, accent boxes, and thelike.

The various aspects of the present invention can be further illustratedand described by the following Examples. It should be understood,however, that these Examples is included merely for purposes ofillustration and is not intended to limit the scope of the invention,unless otherwise specifically indicated.

EXAMPLES Example 1: Measurement of Screw Withdrawal Force fromReinforced Recess

Three samples each of five different substrates, including four types ofparticle board with ANSI grades M-0, M-1, M-S, and M-2, and mediumdensity fiberboard were assembled. One sample of each of the five typesof substrates was coated with EASTMAN™ CS10-1201IF white resincommercially available from Eastman Chemical Company (Tennessee, USA) toan average coating thickness of approximately 0.012 inches.

The screw withdrawal force required to remove a one-inch, #10 type ABscrew from the each of the uncoated and coated samples for each type ofsubstrate was measured according to ASTM D1037, Section 16. The leadhole diameter was 0.125 inches and the screw penetration depth was 0.667inches. The results are summarized in Table 2, below.

TABLE 1 Results of Screw Withdrawal Force Testing Sample Coated, lb_(f)Uncoated, lb_(f) ANSI M-0 258 273 ANSI M-1 239 214 ANSI M-S 261 266 ANSIM-2 328 362

Another sample of MDF was obtained and a channel measuring approximately0.75 by 0.375 inches was cut into center portion of the substrate. Thechanneled substrate was then coated with the coating material describedin Table 1, and the average screw withdrawal force for a screw insertedinto the central portion of the coated channel was measured as describedabove. Table 2, below, summarizes the results for the screw withdrawalforce test for the coated MDF samples with and without a channel overseveral runs.

TABLE 2 Screw Withdrawal Force for MDF With and Without Channel MDFWithout Channel MDF With Channel Run Withdrawal Force, lb_(f) WithdrawalForce, lb_(f) 1 263 478 2 286 532 Average 275 505

Example 2: Preparation of Substrates for Strength Testing

Several substrates each having cross-sectional shapes similar to thesplit jamb substrate 1764 illustrated in FIGS. 61-63 were formed usingmedium density fiberboard (MDF) with an average a density between 42 and51 lb/ft³. The fiber board, which is commercially available fromLangboard, Inc. (Georgia, USA), was formed into 18 individualsubstrates, each having a nominal length, designated as L_(s) in FIG.63, of about 3 inches and a nominal thickness, shown as dimension T_(s)in FIG. 63, of about 0.35 to about 0.37 inches. Additionally, six othersubstrates having a similar cross-sectional shape were also formed usingfinger-jointed pine (FJP) with the same nominal dimensions. The exactdimensions of each of these substrate are provided in Table 3, below.

Three of the MDF substrates and three FJP substrates, respectivelylabeled CO-1 through CO-3 and CO-4 through CO-6 in Table 4 below, wereretained as controls and were not coated. The remaining MDF and FJPsubstrates were divided first by material and then into groups of threeand were coated, in triplicate, with several different coatings. A latexpaint, commercially available as BEHR Ultra Pure White 3050 InteriorSemi-Gloss Enamel from Behr Process Corporation, was used to as acomparative coating material and was used to coat three of the MDFsubstrates to an average thickness of 9 mils (e.g., Substrates C-1through C-3) and three others to an average thickness of 12 mils (e.g.,Substrates C-4 through C-6).

The remaining MDF substrates, labeled I-1 through I-9 in Table 4, andthe three FJP substrates, labeled I-10 through I-12 in Table 4, werecoated with one of two resin-containing coating materials using anextrusion coating process as described below. The first resin-containingcoating material (Coating A) was EASTMAN™ CS10-1201IF white resincommercially available from Eastman Chemical Company, and the secondresin-containing coating material (Coating B) was an impact-modifiedacrylic polymer, OPTIX CA 1000E-2, commercially available fromPlaskolite, Inc. Coating A was applied to six of the MDF substrates(e.g., Substrates I-1 through I-6) and three of the FJP substrates(e.g., Substrates I-10 through I-12), and Coating B was applied to theremaining three MDF substrates (e.g., Substrates I-7 through I-9).Average thicknesses of the coatings applied to each of Substrates I-1through I-12 are summarized in Table 4 below.

After being preheated in an oven and held in a staging area, SubstratesI-1 through I-12 were individually passed through a die assembly thatincluded a die outlet conforming to the cross-sectional shape of each ofSubstrates I-1 through I-12. Coating A was fed through a 2½ inchextruder during the coating of Substrates I-1 through I-6 and I-9thorough I-12, and Coating B was similarly applied to Substrates I-7through I-9. During application of Coating A to Substrates I-1 throughI-6 and I-9 through I-12, the melt temperature was held at 500° F.,while the melt temperature of Coating B applied to Substrates I-7through I-9 was maintained at 550° F. In both cases, the die temperaturewas the same as the melt temperature, and the melt pressure was between400 and 900 psi. Upon removal from the die assembly, each of thesubstrates was allowed to cool. Substrates I-1 through I-3 had anaverage coating thickness of 16 mils, while the average coatingthickness of Substrates I-4 through I-6 was 23 mils. Substrates I-7through I-9 had an average coating thickness of 25 mils, and SubstratesI-10 through I-12 had an average coating thickness of about 11 mils.

Four additional samples were prepared, each having a substrate shapedsimilarly to substrate 1822 shown in FIG. 64. Each of these samples,which were portions of a wainscot panel, was formed from high densityfiberboard having an average density between 51 and 62 lb/ft³. Each ofsubstrate had a nominal length of 3 inches and a nominal thickness of0.1 inches. The exact dimensions of each sample are provided in Table 4,below.

One of the substrates, labeled CO-7 in Table 4, was retained as acontrol and was left uncoated. Substrate C-7 was painted with the BEHRUltra White latex paint as described previously and, upon drying, had anaverage paint thickness of 5 mils. The remaining two substrates, I-13and I-14, were extrusion coated with respective Coatings A and B, asdescribed previously. Both substrates had an average coating thicknessof 11 mils.

Each of the Substrates CO-1 through CO-7, C-1 through C-7, and I-1through I-14 were then subjected to strength testing as described inExample 3, below.

Example 3: Strength Testing of Coated and Uncoated Substrates

Each of the substrates prepared in Example 2 above were separatelysubjected to a strength test to determine the peak (maximum) load (inpounds-force) and peak (maximum) stress (in pounds per square inch)achievable by each substrate, according to the following method.

Control Substrate CO-1 was placed in a 50 kN MTS Insight materialtesting frame having a 0.629-inch diameter compression probe, shown asprobe 1920 in FIGS. 65a-c . The first control Substrate CO-1 wasarranged in a “flush” position such that the outer edge of thecompression probe 1920 was parallel with the outer edge of the substrateCO-1, as shown in FIG. 65a and compression of the substrate was theninitiated at a speed of 0.20 inches per minute. During compression, theload (force) and pressure applied to the substrate via compression probe1920 was measured and recorded using the MTS Simplified CompressionMethod run using the TestWorks software package (commercially availablefrom MTS Systems Corporation, Eden Prairie, Minn.).

Compression of the substrate was continued until the substrate broke orcracked and the maximum load and pressure achieved just prior tobreakage were recorded as the peak load and pressure. Tests wereconducted in a similar manner with the two other uncoated substrates,CO-2 and CO-3, except the position of compression probe 1920 was varied.As shown in FIG. 65b , Substrate CO-2 was tested with the probe 1920 ina “half” position, such that the mid-line of the probe was resting onthe outer edge of Substrate CO-2, while Substrate CO-3 was tested in an“outer” position, such that the other edge of probe 1920 is parallel toSubstrate CO-3, as shown in FIG. 65c . Results for the peak load andpeak stress for each of Substrates CO-1 through CO-3 are summarized inTable 4, below.

Similar strength tests were carried out on Substrates CO-4 through CO-6(uncoated FJP), Substrates C-1 through C-3 (9 mil thick paint on MDF),Substrates C-4 through C-6 (12 mil thick paint on MDF), Substrates I-1through I-3 (16 mil thick Coating A on MDF), Substrates I-4 through I-6(23 mil thick Coating B on MDF), Substrates I-7 through I-9 (25 milthick Coating B on MDF), and Substrates I-10 through I-12 (11 mil thickCoating Aon FJP).

One substrate from each group (Substrates C-1, C-4, I-1, I-4, I-7, andI-10) was tested in a flush position, one substrate from each group(e.g., Substrates C-2, C-5, I-2, I-5, I-8, and I-11) was tested in ahalf position, and one substrate from each group (e.g., Substrates C-3,C-6, I-3, I-6, I-9, and I-12) was tested in an outer position. Inaddition to measuring the peak load and peak stress for each painted orcoated substrate, increase in peak stress, as compared to the uncoatedsubstrate tested in the same position (i.e., flush, half, or outer), wasalso calculated according to the following formula: (Peak Stress CoatedSubstrate−Peak Stress of Uncoated Substrate)/(Peak Stress (psi) ofUncoated Substrate), expressed as a percentage. Values for peak load,peak stress, and peak stress increase, measured in the flush, half, andouter positions, for each of the coated substrates C-1 through C-6 andI-1 through I-12 are provided in Table 4, below.

TABLE 4 Strength Test Results for Several Substrates Substrate DimensionPeak Coating Overall Protrusion Peak Peak Stress Thickness Test LengthThickness Load Stress Increase Functional Substrate Material Type (mils)Configuration (inches) (inches) (lb_(f)) (psi) (%) Part? CO-1 MDF None —Flush 2.966 0.351 10.51 10.06 — N CO-4 FJP None — Flush 2.958 0.34033.892 33.620 — — C-1 MDF Paint  9 Flush 2.989 0.361 12.70 11.78 17 NC-4 MDF Paint 12 Flush 2.998 0.363 14.83 13.62 35 N I-7 MDF Coating B 25Flush 2.960 0.373 28.12 25.48 153 Y I-1 MDF Coating A 16 Flush 3.0300.374 33.99 29.98 198 Y I-4 MDF Coating A 23 Flush 2.978 0.374 29.4226.48 163 Y I-10 FJP Coating A 11 Flush 2.986 0.379 57.994 51.260 57 —CO-2 MDF None — Half 2.918 0.351 6.588 6.48 — N CO-5 FJP None — Half2.918 0.341 17.776 17.840 — — C-2 MDF Paint  9 Half 2.994 0.360 7.2806.78 5 N C-5 MDF Paint 12 Half 3.012 0.360 7.990 7.360 14 Y I-8 MDFCoating B 25 Half 2.950 0.373 17.18 15.58 140 Y I-2 MDF Coating A 16Half 3.028 0.375 19.52 17.23 166 Y I-5 MDF Coating A 23 Half 2.962 0.37317.93 16.24 151 Y I-11 FJP Coating A 11 Half 3.004 0.378 31.914 28.10080 — CO-3 MDF None — Outer 2.971 0.347 5.642 5.46 — N CO-6 FJP None —Outer 2.948 0.341 15.682 15.600 — — C-3 MDF Paint  9 Outer 2.995 0.3625.621 5.20 −5 N C-6 MDF Paint 12 Outer 3.003 0.363 5.836 5.36 −2 N I-9MDF Coating B 25 Outer 2.951 0.372 13.31 12.10 122 Y I-3 MDF Coating A16 Outer 3.028 0.375 15.34 13.53 148 Y I-6 MDF Coating A 23 Outer 2.9590.373 14.25 12.90 136 Y I-12 FJP Coating A 11 Outer 2.986 0.377 25.35422.520 62 —

In addition, each of Substrates CO-7, C-7, I-13, and I-14 was alsostrength tested in a similar manner, except each was only tested in anouter position. The results for peak load, peak stress, and peak stressincrease for Substrates CO-7, C-7, I-13, and I-14 are summarized inTable 5, below.

TABLE 5 Strength Test Results for Additional Substrates SubstrateDimension Peak Coating Overall Protrusion Peak Stress Thickness LengthThickness Peak Stress Increase Functional Substrate Type (mils) (inches)(inches) Load (lb_(f)) (psi) (%) Part? CO-7 None — 2.965 0.088 29.23111.8 — N C-7 Paint 5 2.979 0.099 25.42 86.10 −23 N I-13 Coating A 112.984 0.099 53.66 180.7 62 Y I-14 Coating B 11 2.956 0.103 62.95 207.285 Y

Additionally, after testing, each substrate was visually examined todetermine whether or not, once cracked, it could be used. The results ofthese visual observations for each of the substrates tested aresummarized in the last columns of Tables 4 and 5. As shown particularlyin Table 4, increasing the paint thickness by 33 percent (from 9 mils to12 mils) has no observable impact on the strength of the paintedsubstrate. It is not expected that further increases to the paintthickness would show different results, in particular because of thediscontinuous microstructure of paint.

The preferred forms of the invention described above are to be used asillustration only, and should not be used in a limiting sense tointerpret the scope of the present invention. Obvious modifications tothe exemplary embodiments, set forth above, could be readily made bythose skilled in the art without departing from the spirit of thepresent invention.

The inventors hereby state their intent to rely on the Doctrine ofEquivalents to determine and assess the reasonably fair scope of thepresent invention as pertains to any apparatus not materially departingfrom but outside the literal scope of the invention as set forth in thefollowing claims.

We claim:
 1. A method of making an extrusion-coated structural system,said method comprising: extrusion coating a coating material onto atleast a portion of a first substrate to form an extrusion-coatedstructural member, wherein said first substrate defines at least onestructural recess extending inwardly from an outer surface of said firstsubstrate and a near-recess external surface adjacent said structuralrecess, wherein said near-recess external surface is formed of saidcoating material during said extrusion coating, wherein said extrusioncoating includes applying said coating material to said structuralrecess so that the maximum thickness of said coating material withinsaid structural recess is at least 2 times greater than the thickness ofsaid coating material forming said near-recess external surface.
 2. Themethod of claim 1, wherein said extrusion coating includes applying saidcoating material to said structural recess so that the maximum thicknessof said coating material within said structural recess is at least 5times greater than the thickness of said coating material forming saidnear-recess external surface.
 3. The method of claim 1, wherein saidextrusion coating includes applying said coating material to saidstructural recess so that at least 50 percent of the total volume ofsaid structural recess is filled with said coating material.
 4. Themethod of claim 1, wherein said first substrate is formed of a firstsubstrate material, wherein the elasticity of said coating material isgreater than the elasticity of said first substrate material.
 5. Themethod of claim 1, wherein the ratio of the maximum depth of saidstructural recess to the dimension of said substrate parallel to thedepth of said structural recess is in the range of from about 0.1:1 toabout 0.90:1.
 6. The method of claim 1, wherein said substrate furthercomprises one or more additional structural recesses extending inwardlyfrom another portion of said outer surface of said substrate, whereinsaid additional structural recess has been at least partially coatedwith said coating material so as to reinforce at least another portionof said substrate, wherein at least 50 percent of the total volume ofsaid additional structural recess is filled with said coating material.7. The method of claim 1, further comprising, prior to said extrusioncoating, pretreating a precursor substrate to form said first substrate,wherein said pretreating includes forming said structural recess withinsaid first substrate; further comprising subsequent to said extrusioncoating, cooling said extrusion-coated structural member in a quenchzone to form a cooled extrusion-coated structural member.
 8. The methodof claim 1, wherein said coating material has a glass transitiontemperature in the range of from about 60° C. to about 150° C.
 9. Themethod of claim 1, wherein said substrate comprises natural wood,medium-density fiberboard, particle board, oriented strand board,plastic, cellularized PVC, foam, metal, fiberglass-reinforced thermosetor thermoplastic polymers, or combinations thereof.
 10. The method ofclaim 1, wherein said coating material comprises one or more resinsselected from the group consisting of polyesters, copolyesters,polycarbonates, polymethyl methacrylate (PMMA), impact-modified PMMA,poly(acrylonitrile-styrene-acrylate) (ASA),poly(acrylonitrile-butadiene-styrene) (ABS), poly(styrene-acrylonitrile)(SAN), cellulose esters and mixtures thereof.